Aspen IPE User Guide

Aspen Process Economic Analyzer V7.0 User Guide Version Number: V7.0 July 2008 Copyright (c) 2008 by Aspen Technology, Inc. All rights reserved. Aspen Process Economic Analyzer, the aspen leaf logo and Plantelligence and Enterprise Optimization are trademarks or registered trademarks of Aspen Technology, Inc., Burlington, MA. All other brand and product names are trademarks or registered trademarks of their respective companies. This document is intended as a guide to using AspenTech's software. This documentation contains AspenTech proprietary and confidential information and may not be disclosed, used, or copied without the prior consent of AspenTech or as set forth in the applicable license agreement. Users are solely responsible for the proper use of the software and the application of the results obtained. Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the software may be found in the applicable license agreement between AspenTech and the user. ASPENTECH MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THIS DOCUMENTATION, ITS QUALITY, PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803-5501 USA Phone: 781 221-6400 Toll Free: 888-996-7100 URL: http://www.aspentech.com Contents 1 Introduction .......................................................................................................11 Main Features...............................................................................................11 Links to Process Simulator Software Programs.........................................11 Mapping of Simulator Models to Process Equipment Types.........................11 Sizing of Equipment.............................................................................12 Capital Investment and Schedules: Engineer-Procure-Construct.................12 Development of Operating Costs ...........................................................12 Investment Analysis and Aspen Process Economic Analyzer’s Link to Your Spreadsheets......................................................................................12 Alternative Capacities and Locations ......................................................12 Detailed, Interactive Process Economics .................................................13 Links to Project Evaluation Programs......................................................13 Understanding Aspen Process Economic Analyzer’s Project Workflow ....................13 The Guide ....................................................................................................14 Organization.......................................................................................14 Related Documentation ..................................................................................15 Installation Guide ................................................................................15 Known Issues and Workarounds ............................................................16 New Features in Aspen Engineering V7.0 ................................................16 Icarus Reference .................................................................................16 Piping and Instrumentation Drawings .....................................................16 Technical Support .........................................................................................16 Online Technical Support Center............................................................16 2 Getting Started...................................................................................................17 Starting Aspen Process Economic Analyzer........................................................17 Starting a Project Scenario .............................................................................18 Creating a New Project Scenario............................................................18 Importing an Aspen Process Economic Analyzer 5.0/5.1 Project Scenario ....22 Opening an Existing Project Scenario ...............................................................24 Understanding the Icarus Interface..................................................................26 Project Explorer ..................................................................................26 Main Window ......................................................................................28 List View ............................................................................................30 Palette...............................................................................................32 Properties Window...............................................................................34 Customizing the Icarus Interface ...........................................................35 Aspen Process Economic Analyzer's Toolbar ............................................36 Aspen Process Economic Analyzer Menu Bar............................................38 Working with Project Scenarios .......................................................................42 Saving Project Scenarios ......................................................................42 Deleting Project Scenarios ....................................................................43 1 Introduction 3 Salvaging Project Scenarios ..................................................................44 Unlocking Project Scenarios ..................................................................45 Copying Project Directories ...................................................................46 Preferences ..................................................................................................46 General..............................................................................................47 Forms................................................................................................48 Backup ..............................................................................................49 Process ..............................................................................................49 Locations ...........................................................................................50 Logging .............................................................................................53 3 Defining the Project Basis ..................................................................................55 Project Properties..........................................................................................56 General Project Data .....................................................................................57 Importing old Standard basis files ...................................................................58 Basis for Capital Costs ...................................................................................58 Input Units of Measure Customization ....................................................59 Output (Reports) Units of Measure Customization ....................................61 General Specs ....................................................................................62 Construction Workforce ........................................................................70 Indexing ............................................................................................74 Process Design .............................................................................................77 Simulator Type and Simulator File Name ................................................77 Simulator Units of Measure Mapping Specs .............................................77 Project Component Map Specifications....................................................80 Default Simulator Mapping Specs...........................................................82 Design Criteria ....................................................................................86 Utility Specifications ............................................................................98 Investment Analysis .................................................................................... 101 Investment Parameters ...................................................................... 101 Operating Unit Costs.......................................................................... 107 Raw Material Specifications................................................................. 108 Product Specifications ........................................................................ 111 Developing Streams .................................................................................... 114 Viewing or Modifying an Existing Stream............................................... 115 Mixture Specs Dialog Box ................................................................... 118 Estimation of Utility Usage and Resulting Costs in Aspen Process Economic Analyzer .......................................................................................... 119 Stream Connectivity .......................................................................... 120 Creating A New Stream ...................................................................... 121 Deleting a Stream ............................................................................. 124 Specification Libraries .................................................................................. 125 Customizing Specification Libraries ...................................................... 126 Selecting to Use a Different Specification File ........................................ 129 Changing File Directory Location.......................................................... 129 4 Loading and Mapping Simulation Data .............................................................131 Overview ................................................................................................... 131 Preparing Simulation Reports ........................................................................ 131 AspenPlus Report Generation .............................................................. 132 AspenPlus – Aspen Process Economic Analyzer Simulator link .................. 135 ChemCAD Report Generation .............................................................. 136 1 Introduction 4 HYSIM Report Generation ................................................................... 137 HYSYS Report Generation ................................................................... 139 SimSci’s PRO/II with PROVISION Report Generation............................... 141 Loading Simulation Data .............................................................................. 143 Viewing Data Derived from Simulator ................................................... 145 Working with Block Flow Diagrams ................................................................ 146 Displaying the Block Flow Diagram....................................................... 146 The Drag & Find Feature .................................................................... 147 Accessing Commands in the Block Flow Diagram.................................... 148 Zooming .......................................................................................... 148 BlockFlow Diagram View Menu ............................................................ 150 Mapping Simulator Items to Icarus Project Components ................................... 151 Component Status............................................................................. 157 Deleting Mappings ............................................................................. 158 Tower Configurations................................................................................... 158 Sizing Selection .......................................................................................... 169 Project Sizing Selection ................................................................................ 169 Specifying Additional Components ................................................................. 171 Working with Process Flow Diagrams ............................................................. 171 Editing the Layout ............................................................................. 172 Process Flow Diagram View Menu ........................................................ 172 Setting Grid Properties ....................................................................... 175 Editing Connectivity ........................................................................... 175 Adding a Stream ............................................................................... 177 Drawing a Disconnected Stream .......................................................... 179 Working with Streams........................................................................180 5 Defining Project Components ...........................................................................181 Adding an Area ........................................................................................... 182 Adding a Project Component......................................................................... 182 Method 1: Dragging a Component from the Palette ................................ 183 Method 2: Using the Pop-Up Menu ....................................................... 184 Entering Component Specifications ................................................................ 186 Defining Installation Bulks ............................................................................188 Mat’l/Man-hours Adjustments.............................................................. 189 Mat’l/Man-hours Additions .................................................................. 191 Pipe – General Specs ......................................................................... 191 Pipe – Item Details ............................................................................ 191 Duct ................................................................................................ 193 Civil ................................................................................................ 194 Steel ............................................................................................... 194 Instrumentation ................................................................................194 Electrical ..........................................................................................197 Insulation......................................................................................... 197 Paint ...............................................................................................198 Defining Area Specifications..........................................................................198 Method 1: Defining area specifications using Project View ....................... 198 Method 2: Defining area specifications using Spreadsheet View................ 200 Importing Areas and Components.................................................................. 200 Importing an Entire Scenario ........................................................................201 Copying Components ................................................................................... 202 Cut and Paste ................................................................................... 203 1 Introduction 5 Drag and Drop .................................................................................. 203 Modifying Components................................................................................. 203 Copying Areas ............................................................................................204 Deleting Components ..................................................................................204 Re-numbering Components ................................................................ 204 Deleting Areas ............................................................................................205 Re-Numbering Areas.......................................................................... 205 Using the Custom Model Tool ........................................................................ 206 Creating a Template ..........................................................................210 Running the Custom Model Tool at Project-Level for Batch Update............ 211 6 Sizing Project Components...............................................................................213 Overview ................................................................................................... 213 Sizing for Project Components Mapped from Simulator Items .................. 213 Interactive Sizing Expert .................................................................... 214 Sizing for Project Components Not Mapped from Simulator Items............. 215 Resizing Project Components .............................................................. 215 Creating Streams to Connect to Equipment Items ............................................ 216 Using the Interactive Sizing Form .................................................................. 219 Utility Resources ............................................................................... 222 Global Sizing Selection................................................................................. 226 Sizing Areas ............................................................................................... 229 Sizing Requirements, Calculations, and Defaults .............................................. 230 Air Coolers ....................................................................................... 230 Agitated Tanks.................................................................................. 232 Compressors .................................................................................... 233 Crushers ..........................................................................................234 Crystallizers ..................................................................................... 235 Dryers .............................................................................................236 Dust Collectors .................................................................................236 Filters ..............................................................................................237 Heat Exchangers ............................................................................... 238 Pumps ............................................................................................. 240 Screens ........................................................................................... 242 Towers ............................................................................................243 Vessels ............................................................................................255 7 Piping and Instrumentation Models .................................................................263 Interconnecting Volumetric P&ID Lines ........................................................... 263 Open an Aspen Capital Cost Estimator project ....................................... 263 Run Interconnect Piping Lines ............................................................. 264 Connecting Piping Lines...................................................................... 265 Disconnecting Piping Lines .................................................................. 266 Renaming a Line Tag ......................................................................... 267 Saving All Connections and (optionally) Updating the Project ................... 268 Getting the Connected Line List Report ................................................. 268 Mapping Streams to Piping Lines ................................................................... 269 Mapping Streams to Piping Lines ......................................................... 271 Un-mapping Streams to Piping Lines .................................................... 271 Using the Auto-Map Option ................................................................. 272 1 Introduction 6 8 Developing and Using Cost Libraries ................................................................276 Equipment Model Library (EML)..................................................................... 276 Unit Cost Library (UCL) ................................................................................276 Developing and Using an Equipment Model Library (EML).................................. 277 Creating an EML................................................................................ 277 Adding an Item to an EML .................................................................. 278 Adding an EML Item to a Project Scenario............................................. 280 Developing and Using a Unit Cost Library (UCL)............................................... 281 Creating a Unit Cost Library ................................................................ 282 Adding an Item to a UCL .................................................................... 283 Adding a UCL Item to a Project ........................................................... 285 Creating an Assembly of UCL Items ..................................................... 287 Working with Cost Libraries .......................................................................... 291 Copying a Library Item....................................................................... 291 Deleting a Library Item ...................................................................... 291 Escalating Library Costs ..................................................................... 291 Importing a Cost Library .................................................................... 292 Duplicating a Cost Library................................................................... 293 Deleting a Cost Library....................................................................... 294 9 Changing Plant Capacity and Location..............................................................295 Changing Plant Capacity............................................................................... 295 Analyzer Scale-Up Module (ASM)................................................................... 297 How ASM Works................................................................................ 297 Scale-Up Rule Set ............................................................................. 297 Scale-Up for Configuration Analysis...................................................... 298 Analyzer Relocation Module (ARM)................................................................. 298 Relocation Terminology ...................................................................... 299 Workflow ......................................................................................... 299 Relocating the Project ........................................................................ 302 ARM Knowledge Base......................................................................... 303 10 Analyzer Utility Modules.................................................................................311 Introduction ............................................................................................... 311 Analyzer Utility Modules (AUM) – Design and Scope Generators for Utility Systems ..........................................................................................311 AUM_CW: Cooling Water Utility Selection, Sizing, and Design Module ....... 312 AUM_Air: Instrument and Plant Air Utility Selection, Sizing, and Design Module ............................................................................................ 312 Analyzer Utility Module (AUM) Cooling Water (AUM_Water) ............................... 313 Introduction to Analyzer Utility Module (AUM) Cooling Water ................... 313 1. Overview.....................................................................................314 2. Working with the Cooling Water Model............................................. 316 3. Working with the Cooling Water Model Worksheets............................ 322 4. Basis for the Cooling Water Design Model......................................... 330 Notes to Analyzer Utility Model (AUM) Users: ........................................ 340 AUM_Air ....................................................................................................341 Utility Design and Scope Generator for Instrument and Plant Air .............. 341 Overview ................................................................................................... 341 Project areas and their project components........................................... 341 Benefits: .......................................................................................... 342 1 Introduction 7 How AUM_Air Works .......................................................................... 342 General AUM_Air Workflow ........................................................................... 342 Using AUM_Air............................................................................................ 343 Accessing AUM_Air ............................................................................ 343 The Initial Design .............................................................................. 345 Modifying Air – Instrument, Plant Data ................................................. 346 Guide for the Air Utility Model (AUM).............................................................. 349 SPECS Organization Chart .................................................................. 350 About this SPECS Book ...................................................................... 350 About an Air Plant Unit....................................................................... 351 About Distribution Piping for an APU .................................................... 352 Schematic ........................................................................................ 353 Configuration of Air Utility Project Components................................................ 353 Project Components .......................................................................... 354 An “Air Plant Unit” - APU .................................................................... 354 Schematic of an Air Plant Unit ............................................................. 355 General Layout ................................................................................. 355 Multiple Air Plant Units for Multiple Areas .............................................. 356 Compressor Redundancy: Multiple, Stand-by, Start-up ........................... 356 Design Considerations ................................................................................. 357 Units of Measure ............................................................................... 357 Air Utility Area .................................................................................. 357 Air Utility Project Components............................................................. 357 Instrument Air (IA) Requirements: Air Flow Rate ................................... 358 Plant Air (PA) Requirements: Air Flow Rate ........................................... 358 Compressor Model Selection Method .................................................... 359 Interactive Specs ........................................................................................ 362 User Preferences ............................................................................... 363 Equipment Redundancy......................................................................363 Equipment Configurations................................................................... 363 Basis for Design: Preferences - 1 ........................................................ 364 Configuration Layout Method and Distribution........................................ 366 Example layout – group of areas served by APU “A” ............................... 367 Circuit Preferences: Configuration of APUs ........................................... 367 Sample Layouts: One APU .................................................................368 Sample Layouts: Multiple APUs........................................................... 368 Design Methods .......................................................................................... 368 Basis for Sizing Air Distribution Piping .................................................. 368 Sample AUM_Air Worksheets ........................................................................ 370 List of AUM_Air Worksheets ................................................................ 370 Welcome Worksheet .......................................................................... 371 Control Center Worksheet................................................................... 371 Guide Worksheet............................................................................... 372 Status Worksheet.............................................................................. 377 Preferences Worksheet....................................................................... 379 Configuration Part 1: Assignment of Plant Air to Areas Not Requiring Instrument Air ..................................................................................381 Configuration Part 2: Assignment of Areas to an APU.............................. 381 Report – Equipment Component Stats .................................................. 382 Report – Pipe Stats............................................................................384 1 Introduction 8 11 Evaluating the Project ....................................................................................385 Running a Project Evaluation ........................................................................ 385 Reviewing and Revising Process Economics in the Analyzer Economics Module ..... 387 Loading the Analyzer Economics Module (AEM) ...................................... 387 Overview of Workbooks...................................................................... 388 Revising Premises ............................................................................. 397 Saving AEM Workbook ....................................................................... 399 Discussion of Economic Premises ......................................................... 399 Reviewing Results in Aspen Icarus Reporter .................................................... 405 Accessing Aspen Reporter................................................................... 405 Which Report Mode? .......................................................................... 407 Standard Reports .............................................................................. 407 List of Standard Reports ..................................................................... 412 HTML Reports ................................................................................... 415 Management Reports ......................................................................... 417 Excel Reports ...................................................................................420 Data Trending...................................................................................425 Importing Data into Aspen Icarus Reporter ........................................... 428 Creating a User Database ................................................................... 429 Reviewing Results in Icarus Editor ................................................................. 430 Accessing Icarus Editor ...................................................................... 430 Printing a Single Section..................................................................... 431 Icarus Editor Toolbar ......................................................................... 431 Report Sections.................................................................................432 Reviewing Investment Analysis ..................................................................... 439 Viewing Investment Analysis............................................................... 440 Equipment Summary ......................................................................... 440 Project Summary .............................................................................. 441 Cashflow .......................................................................................... 448 Executive Summary........................................................................... 453 Using the Reporting Assistant.............................................................. 455 Steps to customize the Run Summary worksheet:.................................. 459 Aspen Process Economic AnalyzerWB_TRA.xls>>Template worksheet:...... 460 Aspen Process Economic AnalyzerWB_TRA.xls>>User defined functions:... 460 Item Evaluation ..........................................................................................462 Appendix A: Equipment and Slots of those Equipment Affected by Mapping .......465 Index ..................................................................................................................499 1 Introduction 9 1 Introduction 10 1 Introduction Aspen Process Economic Analyzer, formerly known as Icarus Process Evaluator (IPE), is designed to automate the preparation of detailed designs, estimates, investment analysis and schedules from minimum scope definition, whether from process simulation results or sized equipment lists. It lets you evaluate the financial viability of process design concepts in minutes, so that you can get early, detailed answers to the important questions of "How much?", "How long?" and, most importantly, "Why?". Main Features Links to Process Simulator Software Programs Aspen Process Economic Analyzer, formerly known as Aspen Icarus Process Evaluator, uses expert system links to effect the automatic transfer of your process simulator output results. Links are available to process simulator programs from AspenTech, Chemstations, Hyprotech, SimSci and others. Aspen Process Economic Analyzer can link to virtually any commercial and proprietary process simulator program. Mapping of Simulator Models to Process Equipment Types Mapping relates each process simulator model to one or more of Aspen Process Economic Analyzer’s list of several hundred types of process equipment. A simulator heat exchanger model might be mapped to a fin-tube type; a distillation model might be mapped into several items, such as trayed tower, kettle-type reboiler, overhead condenser, and horizontal drum. Aspen Process Economic Analyzer’s expert equipment selection makes the mapping easy, allowing you to map one item at a time or all at once. 1 Introduction 11 Sizing of Equipment Size of equipment is a prerequisite to costing and the results of size calculations performed during process simulation are loaded automatically by Aspen Process Economic Analyzer. With Aspen Process Economic Analyzer, you can revise sizes, enter your values for unsized equipment or develop sizes using Aspen Process Economic Analyzer’s built-in expert sizing programs. Capital Investment and Schedules: Engineer-Procure-Construct Aspen Process Economic Analyzer checks and prepares all of the necessary specifications for detailed design, estimation, scheduling, and economic data. Aspen Process Economic Analyzer contains built-in, up-to-date knowledge bases of: Design, cost and scheduling data, methods and models. Engineering, procurement and construction methods and procedures. Critical path programming for development of design, procure and construct schedules. Aspen Process Economic Analyzer comes with time-proven, field-tested, industry-standard design and cost modeling and scheduling methods used by project evaluators for projects worldwide. Aspen Process Economic Analyzer’s detailed results are not based on factors. Aspen Process Economic Analyzer’s estimates and schedules are consistent, being derived from your project scope definition. Development of Operating Costs Aspen Process Economic Analyzer develops operating costs in tune to your process design. You can override Aspen Process Economic Analyzer’s values and with each revision, you can see the impact of your choice on investment analysis measures of profitability. Investment Analysis and Aspen Process Economic Analyzer’s Link to Your Spreadsheets In addition to Aspen Process Economic Analyzer’s basic measures such as return on investment, payout time and discounted cash flow rate of return, your spreadsheet programs can be linked to Aspen Process Economic Analyzer’s investment analysis data. Alternative Capacities and Locations Analyzer allows you to evaluate alternate plant capacities and locations. You can make a percentage adjustment to the capacity, and Analyzer will 1 Introduction 12 automatically re-size all project components and stream flows. You can change the plant location (choosing from twenty-two different countries), and Analyzer’s plant relocation technology will automatically revise the design and cost basis parameters, including parity exchange rate, workforce rates, productivities, and construction practices. Detailed, Interactive Process Economics Analyzer’s detailed economics module lets you perform interactive economic scenarios. It develops key economic measures, including payout time, interest rate of return, net present value, and income and expenses on changing any economic premise. It performs economic analyses over the time line of a project, from the strategic planning phase through engineering, procurement and construction of the process facility, into start-up and throughout the production life of the process facility. You can study the impact of cyclic changes in market conditions and identify economic threats and opportunities upon changing costs of feedstocks, products and/or utilities for each period in the life of a project. Links to Project Evaluation Programs After your evaluation and selection of the best design, Aspen Process Economic Analyzer can prepare a project specs file in SPECS format. Then, project evaluators using these systems can easily develop detailed funding or bidding estimates and schedules. Understanding Aspen Process Economic Analyzer’s Project Workflow Before using Aspen Process Economic Analyzer, it may be helpful to review the recommended project workflow. 1 Introduction 13 Notes: • This workflow is recommended if you are bringing process simulator data into Aspen Process Economic Analyzer. However, Aspen Process Economic Analyzer lets you perform the same evaluation on a process comprised of areas and components that you add in Aspen Process Economic Analyzer, rather than mapped from simulator models. • During the project workflow, you can go back to previous steps to refine the project. The Guide Organization This guide contains the following: 1 Introduction 14 Chapter 1 − Introduction − an overview of Aspen Process Economic Analyzer and the user's guide, as well as a list of related documentation and information on technical support. Chapter 2 − Getting Started − instructions on how to start Aspen Process Economic Analyzer, open a project, enter project specifications, and work with the Icarus Interface. Chapter 3 − Defining the Project Basis − instructions on defining specifications: units of measure, standard basis, component map, design criteria, investment analysis, raw material, product, operating unit costs, and utility. Chapter 4 − Loading and Mapping Simulation Data − instructions on preparing different kinds of simulator reports for use in Aspen Process Economic Analyzer, loading simulator data, mapping simulator models to Icarus project components, adding additional components to simulator models, and viewing and defining simulator models in Block Flow Diagram (BFD) and Process Flow Diagram (PFD) view. Chapter 5 − Defining Project Components − instructions on defining project components, which are the pieces of the process plant that, when linked together, complete a process. Chapter 6 − Sizing Project Components − instructions on sizing project components. Chapter 7 – Piping and Instrumentation Models – instructions on connection pipelines between components and creating piping line list reports for connected lines. Chapter 8 – Developing and Using Cost Libraries − instructions on developing cost libraries and adding library items as project components. Chapter 9 – Changing Plant Capacity and Location − instructions on modifying plant capacity and locations, as well as details on the parameters affected by these modifications. Chapter 10 - Analyzer Utility Modules – instructions on using Analyzer Utility Modules for cooling water and air. Chapter 11 - Evaluating the Project − instructions on running a project and item evaluations and reviewing capital costs, operating costs, and investment analysis reports. Related Documentation In addition to this document, a number of other documents are provided to help users learn and use Aspen Process Economic Analyzer. The documentation set consists of the following: Installation Guide Aspen Engineering V7.0 Installation Guide 1 Introduction 15 Known Issues and Workarounds Aspen Engineering V7.0 Known Issues New Features in Aspen Engineering V7.0 Aspen Engineering Suite V7.0 What's New Icarus Reference Aspen Icarus Reference Guide, for Icarus Evaluation Engine (IEE) Piping and Instrumentation Drawings IcarusPIDV7.0_Ref.PDF, for Icarus Piping and Instrumentation Drawings Technical Support Online Technical Support Center AspenTech customers with a valid license and software maintenance agreement can register to access the Online Technical Support Center at: http://support.aspentech.com H0TU UTH You use the Online Technical Support Center to: • Access current product documentation. • Search for technical tips, solutions, and frequently asked questions (FAQs). • Search for and download application examples. • Search for and download service packs and product updates. • Submit and track technical issues. • Search for and review known limitations. • Send suggestions. Registered users can also subscribe to our Technical Support e-Bulletins. These e-Bulletins proactively alert you to important technical support information such as: 1 Introduction • Technical advisories • Product updates • Service Pack announcements • Product release announcements 16 2 Getting Started Starting Aspen Process Economic Analyzer After completing the installation, you can start Aspen Process Economic Analyzer. To start Aspen Process Economic Analyzer: 1 Click the Windows Start button, point to Programs, and then point to AspenTech. 2 On the AspenTech menu, point to Economic Evaluation 7.0; then point to Aspen Process Economic Analyzer. Aspen Process Economic Analyzer starts. The Main window, empty because no project is open, appears on the left. The Palette appears in the upper-right and the Properties window appears in the lower-right. 2 Getting Started 17 You can change the position of these windows, as explained later in Customizing the Icarus Interface (page 35). X3H X Starting a Project Scenario Note: Viewing the sample project scenario provided with Aspen Process Economic Analyzer before creating a new one will allow you to familiarize yourself with Aspen Process Economic Analyzer without having to fill out specifications. To open the sample project, follow the instructions under Opening an Existing Project Scenario on page 24. X34H X Creating a New Project Scenario To create a new project scenario: 1 Do one of the following: • On the File menu, click New. -or• Click on the toolbar. The Create New Project dialog box appears. 2 Getting Started 18 Note: You can create scenarios in project directories other than the default one provided by Aspen Process Economic Analyzer. See Preferences – Locations on page 50 for instructions on adding project directories. X35H X 2 Either click an existing project in which to start a new scenario, or enter a new Project Name. Long filenames are accepted, including spaces. However, punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*), are not allowed. 3 Enter the Scenario Name. This is the name of the scenario within the project. As with the Project Name, long filenames are accepted, including spaces, while punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*) are not allowed. If you do not enter a Scenario Name, Aspen Process Economic Analyzer uses “BaseCase” as the default. 4 Click OK. The Project Properties dialog box appears. 5 Enter a Project Description. The description can be up to 500 characters in length and can be comprised of letters, numbers, and punctuation. . The 2 Getting Started 19 description can be edited later by accessing Project Properties from the Project Basis view (see page 56). X36H X 6 In the Units of Measure section, you can keep the default basis of Inch-Pound (IP) or select Metric. The Units of Measure selection cannot be changed after creating the project scenario. 7 If desired, enter more details about the project scenario in the Remarks field. Remarks can be up to 6,000 characters in length and can be comprised of letters, numbers, and punctuation. Remarks can be edited later by accessing Project Properties from the Project Basis view (see page 56). X37H 8 X Click OK. Aspen Process Economic Analyzer displays the Input Units of Measure Specifications dialog box, which allows you to customize the units of measure that appear on specification forms. For example, if you want to use CM/H (centimeters per hour) instead of M/H (meters per hour) to specify conveyor belt speed in your metric-basis project, do the following: 9 Select Velocity and Flow Rate; then click Modify. 10 On the Velocity and Flow Rate Units form, enter CM/H as the new unit name for M/H. Then enter the conversion factor between the two units in the Conversion field. In this example, the conversion factor between the two units is 100 because: 100 CM/H = 1 M/H. 2 Getting Started 20 11 Click OK to accept the modifications and return to the previous dialog box. When finished modifying input units of measure, click Close. Aspen Process Economic Analyzer displays the General Project Data form, where you can select a country base and currency. The default country base is US and the default currency is Dollars (USD). Changing the country base automatically changes the currency to that of the country base. You can, however, enter a currency different than that of the country base. Just be sure to also enter a currency conversion rate (the number of currency units per one country base currency unit). Country base affects various system default values. Chapter 36 of Icarus Reference provides a table listing the default values used for each country base. 2 Getting Started 21 This is the only time you can enter country base and currency. Other specifications on this form can be entered later by selecting General Project Data in the Project Basis view (see page 57). X38H X 12 Click OK when finished entering General Project Data. The Main Window now displays Project Explorer and the List view. See “Understanding the Icarus Interface” on page 26 for instructions on working with these and other features now available on the interface. X39H X Importing an Aspen Process Economic Analyzer 5.0/5.1 Project Scenario Aspen Process Economic Analyzer provides an Import feature so that you can import your Aspen Process Economic Analyzer 5.0 or 5.1 project scenarios into Aspen Process Economic Analyzer V7.0. You can also select an Analyzer 2.0B project scenario to import. The Import feature allows you to use Additional Project Component files in Aspen Process Economic Analyzer V7.0. In order to do so, you must first import the Additional Project Component file into an Aspen Process Economic Analyzer 5.0/5.1 project scenario and then import the Aspen Process Economic Analyzer 5.0/5.1 project scenario into Aspen Process Economic Analyzer V7.0. To import an Aspen Process Economic Analyzer 5.0/5.1 or Analyzer 2.0B project scenario: 1 Do one of the following: • On the File menu, click New. -or• Click on the toolbar. The Create New Project dialog box appears. 2 Getting Started 22 Note: You can create scenarios in project directories other than the default one provided by Aspen In-Plant Cost Estimator. See Preferences – Locations on page 50 for instructions. X340H X 2 Either select an existing project in which to start a new scenario, or enter a new Project Name. Long filenames are accepted, including spaces. However, punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*), are not allowed. 3 Type the Scenario Name. This is the name of the scenario within the project. The selected Aspen Process Economic Analyzer 5.0 or Analyzer 2.0B project file’s project and component specifications will be imported into this scenario. Again, long filenames are accepted, including spaces, while punctuation marks, such as question marks (?), exclamation points (!), tildes (~), and asterisks (*) are not allowed. After making an entry in the Scenario Name field, the Import button becomes active. 4 Click Import. The Select Import Type dialog box appears. 5 Select either Aspen Process Economic Analyzer 5.0 and 5.1 or Analyzer 2.0B and click OK. The Browse for Folder dialog box appears. 2 Getting Started 23 6 Click the project scenario folder; then click OK. The project scenario’s settings will be imported into the new project scenario. Opening an Existing Project Scenario To open an existing project scenario: 1 Do one of the following: • On the File menu, click Open. -or• Click on the toolbar. The Open Existing Project dialog box appears. Note: In the pictured dialog box, the project named Expansion has been expanded on the tree structure to show the scenario named BaseCase. 2 Getting Started 24 The tree structure on the left side of the dialog box displays the projects in the default project folder: ...\AspenTech\Economic Evaluation V7.0\Data\Archives_Aspen Process Economic Analyzer Clicking “+” next to a project expands the view to display the scenarios under that project. Selecting a scenario displays the following scenario information in the pane on the right: 2 o Version of Aspen Process Economic Analyzer in which the scenario was created o Name of the user who created the scenario o Name of the computer on which the scenario was created o Units of measure used in the scenario Click a scenario; then click OK. The project scenario opens. The Main Window now displays Project Explorer and the List view. See “Understanding the Icarus Interface” on page 26 for instructions on working with these and other features now available on the interface. X341H X Palette Shortcut You can also open a project from the Palette, which appears to the right of the Main Window in the default interface arrangement (it can also be floated in the Main Window or dragged onto the Main Window and re-sized, as shown below). To open a project from the Palette : • In the Projects view tab, right-click a scenario; then, on the menu that appears, click Open. This opens the selected scenario. 2 Getting Started 25 Understanding the Icarus Interface The Icarus interface lets you see multiple windows and documents. You can customize the interface arrangement. The following is the default interface arrangement, with a specifications form open in the Main Window. The Icarus interface includes the following features: Title Bar - Displays the project file name and current Main Window view. Menu Bar - Displays menu options. Toolbar - Allows access to Aspen Process Economic Analyzer functions. See page 36. X342H X Main Window - Provides workspace for all Aspen Process Economic Analyzer documents, List view, specification forms, and other views. See page 28. X34H X Project Explorer - Organizes project items in tree format. See page 26. X34H X Palette - Allows access to libraries, projects, and components. See page 32. X345H X Status Bar - Displays Aspen Process Economic Analyzer system status. Properties Window – Describes the field selected on specifications form. See page 32. X346H X Project Explorer Project Explorer is a graphical representation of the project. It has three views: • Project Basis view • Process view • Project view 2 Getting Started 26 Each view organizes items in a tree format. To switch views: • Click the appropriate tab at the bottom of Project Explorer. (Stretching the width of the Project Explorer will display the full names on the tabs.) The different views are described on page 27. X347H X To expand a tree level: • Click the PLUS SIGN next to the condensed level. To condense a tree level: • Click the MINUS SIGN next to the expanded level. Project Explorer Views Project Basis View displays project basis specifications. Double-click on a specification to view and/or modify it. A red arrow on an icon in this view indicates that you can right-click on the icon for options. Level Icon Description 2 Specifications folder 3 Specification Process View displays simulator data information. In this view, simulator items can be mapped to Icarus project components. Mapped items can then be sized, modified, and/or deleted. Level Icon Description 2 Main Project, containing a group of simulator areas 3 Process simulator area 4 Unmapped simulator block (yellow) Mapped simulator block (green) As in a process simulator, like AspenPlus or HYSYS, blocks represent different operations within the process. A block is sometimes referred to as a unit operation. Project View displays project data information. In this view, mapped items can be sized, modified, and/or deleted. In addition, new areas and Icarus project components can be defined. Level Icon Description 1 Main Project, containing the default Main Area and any user-added areas 2 Area 3 Project component 2 Getting Started 27 Main Window The Main Window is located to the right of Project Explorer by default. The Main Window is a workspace for all Aspen Process Economic Analyzer documents, the List view, and other views. The relative size of each window can be adjusted by clicking on the division bar and dragging it to the desired location. Here, the Main Window in Workbook Mode displays several tabs because a component specifications form and a project specifications form have been opened. Workbook Mode By default, the Main Window is in Workbook Mode. In this mode, tabs are placed at the bottom of the window. These tabs represent all windows open in the Main Window. Clicking on a tab brings the associated window to the foreground. Clicking Tile or Cascade on the Window menu displays all windows open in the Main Window. Regardless of the window arrangement, the tabs are still at the bottom of the Main Window when in Workbook Mode. Clicking the maximize button ( ) on a window returns all windows to full tab view. Clicking the condense button ( ) on the menu bar displays all windows open in the Main Window as they were when last condensed. 2 Getting Started 28 This is how the Main Window appears when in Workbook Mode with Cascade selected as the condensed window arrangement. Aspen Process Economic Analyzer lets float Project Explorer, the Palette, and the Properties Window in the Main window. When in this state, these windows behave identically to other windows that are part of the Main Window. See “Customizing the Icarus Interface” on page 35 for details. X348H X You can turn off Workbook Mode by unmarking Workbook Mode on the View menu. When Workbook Mode is off, no tabs are displayed. In this Mode, to bring a window to the front, you must click on the desired window or select the desired window from the Window menu. 2 Getting Started 29 List View The List view in the Main Window displays details on items selected in Project Explorer. For example, when you click on an area in Project Explorer’s Project view, the List view displays a list of all components in the area. This is referred to as the “area-level” list (shown below), in which the components are displayed in rows with component details in columns. When you click on a component in Project Explorer’s Project view, the List provides information only on the selected component, with component details listed in rows. This is referred to as the “component-level”. Note: In the interface arrangement pictured here, the Palette and the Properties Window have been hidden to make room for the Main Window. to press hide or display the Palette ALT+1 hide or display the Properties Window ALT+2 hide or display Project Explorer ALT+0 Filtering Mechanism You can limit area-level lists to a single category of component. To do so, click the drop-down arrow on the toolbar and click on a category. 2 Getting Started 30 For example, if you click “? Incomplete Items,” the list will only include components that still have specifications that need to be entered in order for the component to be included in an evaluation. Column Settings You can select which columns appear on the area-level list and in which order. To change column settings on the area-level list: 1 Right-click on any of the column headings. A pop-up menu lists all of the columns. Columns currently displayed are checked. 2 To simply hide/unhide a column, click it on the menu. 3 To change the order, click Settings on the menu. The Settings dialog box appears. • To move a column to the right on the List View, click Move Down. • To move a column to the left, click Move Up. 2 Getting Started 31 • To return the columns to the default setting (shown above), click Reset. 4 Click OK to save the settings. When you restart Aspen Process Economic Analyzer, all columns will be displayed in the default order unless Save Window States is selected in Preferences (by default, Save Window States is selected). See “Saving Window States” on page 36 for more information. X349H650 Palette The Palette contains elements that you can apply to the project scenario. If you think of Project Explorer as a picture of the project scenario, you might think of the Palette’s contents as the pigments and dyes used to first sketch out and then color in that picture. For example, if you wish to import areas or components from another scenario into your current scenario, you can double-click on the scenario in the Palette to get a listing of its areas and components and then drag the area/component to the Project Explorer’s Project View. (See “Importing Areas and Components” on 198.) 351H Likewise, the Palette’s Libraries view contains libraries of Project Basis specification files that, in Project Explorer’s Project Basis view, you can select to use. From the Palette, you can develop the libraries by creating new files, modifying existing files, and importing files. (See “Specification Libraries” on page 125.) X352H 2 Getting Started X 32 Finally, when you add a component to the project scenario, you can choose from the components listed in the Palette’s Components view. Then, after you add the component, it appears in Project Explorer’s Project view. (See “Adding a Project Component” on page 182). X35H X In the default interface arrangement, the Palette appears on the right side of the screen. Like Project Explorer, it can be displayed in a variety of ways. See “Customizing the Icarus Interface” (page 35) for display options. To hide/display the Palette, press ALT+1 or used the checked command on the View menu. X354H X As indicated previously, the Palette has three views: Projects, Libraries, and Components. The Components view, shown below, has a scrollable split window that displays details on equipment items. The division bar can be adjusted to hide or expand the details section. Note: The Palette pictured in this section has been dragged onto the Main Window and re-sized. In addition to allowing you to import the contents of other scenarios, the Projects view provides options for opening scenarios, viewing scenario properties, and deleting scenarios. Right-click on a project scenario to access the pop-up menu of options. The Projects view displays all projects in the 2 Getting Started 33 default project folder and any other active project folders. (See “Preferences,” particularly the “Locations” subsection on page 50, for instructions.) X35H X Properties Window When you select a field on a specifications form, the Properties Window provides a description of the field. The description often includes minimum, maximum, and default values. Here, the Properties Window (docked on the right side of the screen) displays information on the Heat Transfer Area field, which is selected on the specifications form. Clicking on the Properties Window freezes and unfreezes the content. When the content is frozen, you can move to another field while retaining the description of the original field in the Properties Window. 2 Getting Started 34 Like the Palette and Project Explorer, the Properties Window can be displayed in a variety of ways. See “Customizing the Icarus Interface” on page 35 for display options. X356H X To hide/display the Properties Window, press ALT+2 or use the checked command on the View menu. Customizing the Icarus Interface In the default interface arrangement, Project Explorer docks to the left edge and the Palette and the Properties Window share the right. When docked, windows remain attached to an edge and all other windows are sized to fit in the remaining space available. Clicking on a border of any of these three windows accesses a pop-up menu from which you can select Allow Docking. When Allow Docking is marked, the window can be docked to any edge. Note: When the Float In Main window is selected on the pop-up menu, the Allow Docking option is inactive. To dock to a different edge: 1 Click the border that contains the Close button ( ) and hold down the mouse button. A bounding outline will appear as you drag the window. 2 Drag the outline to the desired edge and release the mouse button. 2 Getting Started 35 When multiple windows are docked to the same edge, you can use the division bar to adjust the relative sizes. You can also use the Contract/Expand ( / ) buttons to either switch from one window to the other or split the side. Undocking by Dragging onto Main Window One way to undock the window is by dragging it onto the Main Window. Its size can then be adjusted. Float In Main Window Option You can at any time select Float In Main Window on the pop-up menu. In this state, the window behaves like the List view or a specifications form, with a tab at the bottom of the Main Window. Saving Window States If you are using the default Preferences, Aspen Process Economic Analyzer will save the interface arrangement. This way, when you open Aspen Process Economic Analyzer the arrangement is the same as you left it. You can also set the Preferences so that Aspen Process Economic Analyzer opens displaying the default arrangement. See “Preferences,” particularly the subsection on the General tab view (page 47), for more information. X357H X Aspen Process Economic Analyzer's Toolbar By default, the toolbar is docked under the menu bar. However, you can float the toolbar by clicking on a blank area of the toolbar and dragging it. You can also dock the toolbar to the bottom of the screen or vertically to the edge of the Project Explorer, Main Window, or the Palette. To do so, drag the toolbar over any one of these areas until an outline of the toolbar appears. Release the mouse button when the outline appears in the desired area. 2 Getting Started 36 The following toolbar buttons are available in Aspen Process Economic Analyzer: Click this to Create a new project scenario. See “Creating a New Project Scenario” on page 18. X358H X Open an existing project scenario. See “Opening an Existing Project Scenario” on page 24. X359H X Save the current project. See “Saving a Project Scenario” on page 42. X360H X Print. Load simulator data. See “Loading Simulator Data” on page 143. X361H X Map simulator items to corresponding Icarus project components and size the component. See “Mapping Simulator Items” on page 151. X362H X Run project evaluation. See page 385 for instructions. X36H X Load Capital Costs and other reports. See page 405 for instructions. X364H X Load investment analysis results. See page 439 for instructions. X365H X Edit connectivity in Process Flow Diagram (PFD) view. See on “Editing Connectivity” on page 175. X36H X Add stream in PFD view. See “Adding a Stream” on page 177. X367H X X368H X Draw disconnected stream in PFD view. See “Drawing a Disconnected Stream” on page 179. X369H X X370H X Zoom in. Active in PFD and Block Flow Diagram (BFD) view. Zoom out. Active in PFD and BFD view. Hide/Display ports in PFD view. Go back. Navigate back through previously viewed links. Go forward. Navigate forward through previously viewed links. Other buttons that appear on the toolbar are always inactive in Aspen Process Economic Analyzer. They are for use in other Icarus programs. 2 Getting Started 37 Aspen Process Economic Analyzer Menu Bar File Menu Click this to New Start a new project scenario. Details on page 18. Open Open an existing project scenario. Details on page 24. Close Close the current project scenario. Save Save the current project scenario. Details on page 42. Save As Save the current project scenario as a different file. Details on page 42. X371H X X372H X37H X X X374H Import X Access instructions for importing areas and components. Details on page 200. X375H X Export to Icarus 2000 Save the current project scenario as an Icarus 2000 (*.ic2) project file. Print Print the form or report currently active in the Main Window. Print Preview Preview how form or report will appear printed. Print Setup View and modify printer name and properties, paper size and source, and orientation. Page Setup Define page specifications. Exit Close Aspen Process Economic Analyzer. 2 Getting Started 38 Run Menu Click this to Load Data Load simulator data. See page 143 for details. Map Items Map simulator items to Icarus project components and size components. See page 151 for details. X376H X37H X X Evaluate Project Run a project evaluation. See page 385 for details. Develop Schedule This sub-menu contains commands for use in Aspen In-Plant Cost Estimator only. Scan for Errors Scan for potential errors in the project evaluation. Add Entry for Reporting Assistant Generate report based on template in Reporting Assistant. See pages 455 through 455 for instructions. Regenerate Block Diagram Regenerate the Block Flow Diagram. If you have indicated that some of the simulator streams are utility streams, the placement of blocks will reflect this. Regenerate Process Flow Diagram Regenerate the Process Flow Diagram. See “Working with Process Flow Diagrams,” page 171, for details. Reroute All Streams Reroute all streams on the Process Flow Diagram. Re-number Re-number project components or project areas so that the numbering contains no gaps. Details on page 204. X378H X379H X X380H X X X381H X X382H 2 Getting Started X 39 View Menu Click this to Toolbar View or hide the toolbar. See page 36 for description of the toolbar. Status Bar View or hide the status bar. See page 26 for description of the status bar. Project Explorer View or hide Project Explorer. See page 26 for description of Project Explorer. Palette View or hide the Palette. See page 32 for description of the Palette. Properties Window View or hide the Properties Window. See page 32 for a description of the Properties Window. Workbook Mode Turn Workbook Mode on and off. See page 28 for an explanation of Workbook Mode. Capital Costs View Launch Aspen Icarus Reporter for interactive reports (on-screen, HTML, or Excel) or Icarus Editor for evaluation reports (.ccp). The Project Evaluation needs to have already been run. See page 405 and page 430 for details. X38H X X384H X385H X X386H X X X387H X38H X X X389H X390H X X Investment Analysis View Display Investment Analysis spreadsheets. See “Reviewing Investment Analysis” on page 439 for details. Block Flow Diagram Display Block Flow Diagram of the loaded simulator data. See page 146 for details. Process Flow Diagram Display Process Flow Diagram. This command is not active until you have mapped the simulator items. See page 171 for details. Streams List Display a read-only list of all simulator-derived stream properties in a spreadsheet. You can customize some of the features of the spreadsheet (which stream properties to display, whether to display names of the properties, and the display style of the property values) by editing the stream list template file: X391H X392H X X X39H X ...\ Economic Evaluation V7.0\Data\ICS\strlist.fil Error Messages 2 Getting Started Display error messages found in the last Capital Costs evaluation. 40 Tools Menu Click this to Icarus Editor Launch Icarus Editor. See “Reviewing Results in Icarus Editor” on page 430 for instructions. X394H X External Simulation Import Tool Access the simulator link for importing simulation data. See page 139 for instructions on using this tool with HYSYS. Options Access Options sub-menu. See below. X395H X Options Sub-Menu of Tools Menu Click this to Automatic Item Evaluation Automatic Item Evaluation View Spreadsheets in Excel Have the results normally reported in Icarus spreadsheets exported to Excel. The following Excel workbook, containing some Excel macros, is provided as a sample: ...\ Economic Evaluation V7.0\Data\ICS\IpeWb.xls A copy of this workbook also resides in each project directory. When Aspen Process Economic Analyzer needs to report the results (that is, when you click the Investment Analysis button), the results will be exported to ASCII delimited files and loaded into IpeWb.xls. The macro contained in the workbook will also be run. Reporting Assistant Access the Reporting Assistant Options dialog box, where you can create your own customized report spreadsheets, combining information from all other Icarus generated spreadsheets. See pages 455 through 455 for details. X396H X X397H X Custom Tasks This command is reserved for future releases. Preferences Access Preferences. See page 47 for details. 2 Getting Started X398H X 41 Window Menu Click this to Cascade View the Main Window contents in Cascade mode. See page 28. Tile View the Main Window contents in Tile mode. See page 28. Arrange Icons Return all minimized windows to the bottom of the Main Window. # XXX View opened window in the Main Window. X39H X40H X X Help Menu Click this to Contents Access Aspen Icarus Online Help. Documentation Display list of available documentation. Training Display training information. Product Support on the Web Display product support information. About Display program information and copyright. Working with Project Scenarios This section explains how to save, delete, salvage, and unlock project scenarios. Saving Project Scenarios To save a project scenario: • 2 Getting Started Click on the toolbar or click Save on the File menu. 42 Aspen Process Economic Analyzer saves any changes. If you are using the default Preferences settings, Aspen Process Economic Analyzer will ask if you wish to save any changes when you close the project scenario. You can select in Preferences not to have this prompt appear (see page 47). X401H X To save the scenario with a new name: 1 Click Save As on the File menu. Save As is useful when studying alternatives. Note: You can save scenarios to project directories other than the default one provided by Aspen Process Economic Analyzer. See “Preferences,” particularly the “Locations” subsection on page 50, for instructions. X402H 2 X Specify a Project Name and Scenario Name and click OK. Aspen Process Economic Analyzer saves the scenario as specified. Deleting Project Scenarios Delete project scenarios when they are no longer needed. Deleting old scenarios opens free disk space and makes working with scenarios easier. To delete a project scenario: 1 2 Getting Started In the project directory, right-click the scenario within and, on the menu that appears, click Delete. 43 A dialog box asks you to confirm deletion. Note: You can select in Preferences not to have this prompt appear (see page 47). X403H 2 X Click Yes to delete the project scenario. -orClick No to retain the project scenario. Salvaging Project Scenarios If you exit Aspen Process Economic Analyzer abnormally without being able to save the current project scenario, you can salvage the project scenario from cached project information. To salvage a project scenario 1 Restart Aspen Process Economic Analyzer. A window appears asking if you wish to save the cached information found in storage. 2 Getting Started 44 2 Click Yes. Aspen Process Economic Analyzer displays the Salvage Project As dialog box. 3 Specify a project and scenario name. You cannot overwrite the scenario being salvaged. Y you must specify a project and scenario name different from that of the original scenario. 4 Click OK. Aspen Process Economic Analyzer creates the new scenario. Except in name, this project scenario is identical to the scenario that was open when Aspen Process Economic Analyzer was abnormally exited. After creating the new scenario, Aspen Process Economic Analyzer asks if you want to open it. Unlocking Project Scenarios If Aspen Process Economic Analyzer crashes while you have a project scenario open, Aspen Process Economic Analyzer remembers that you have the project scenario checked out. When you re-open Aspen Process Economic Analyzer, you will have to unlock the project scenario before opening it. Anyone trying to open a locked project is denied access and provided with a message that states the time the project scenario was checked out, the user name of the person who checked it out, and the computer on which it was checked out. A project can only be unlocked by the user who checked it out or by an administrator. 2 Getting Started 45 To unlock a project scenario • Right-click on the project scenario in the Palette and click Unlock on the pop-up menu. You can now open the project scenario as you normally would. Copying Project Directories Within a project directory, Aspen Process Economic Analyzer creates an independent folder for each project and also creates, within a project folder, an independent folder for each project scenario. This makes it easy to move project scenario files from one computer to another on the same network. Simply copy and paste the folder in Windows Explorer. You can also copy an entire project directory with multiple project and project scenario folders. Doing so creates an identical set of folders and files in the new location. Note: You can copy project directories only in Aspen Process Economic Analyzer V7.0. To use an Aspen Process Economic Analyzer 5.0/5.1 project scenario, you must import it first (see page 22 for instructions). X40H X See “Preferences,” particularly the “Locations” subsection on page 50, for information on adding project directories and setting a new default project directory. X405H X Preferences The settings in Preferences allow you to specify how Aspen Process Economic Analyzer will act each time it is used. To access Preferences: U 1 On the Tools menu, click Options. 2 On the menu that appears, click Preferences. 2 Getting Started 46 Aspen Process Economic Analyzer displays the Preferences dialog box. Click To do this OK Save changes and close the Preferences. Apply Save changes without closing Preferences. Cancel Close Preferences without saving changes. (Clicking Apply and then immediately clicking Cancel would have the same effect as clicking OK.) General In the General tab view, you can select the following: Prompts Select which prompts appear. Close Project – prompt to save any changes when closing project. Overwrite Project – prompt to confirm overwriting project that has the same name as the one being created. Delete Project – prompt to confirm deletion of project. Delete Area – prompt to confirm deletion of area. Delete Component – prompt to confirm deletion of component. Cancel Component Edit – prompt to save changes when you click Cancel after editing a Component Specifications form. Delete Library – prompt to confirm deletion of library. 2 Getting Started 47 Delete Report Group – prompt to confirm deletion of Report Group in Aspen Capital Cost Estimator. Does not apply to Aspen Process Economic Analyzer. Evaluation Display results after evaluation - mark to have Aspen Process Economic Analyzer open a detailed results report after you run an evaluation. Scan for Errors before evaluation – mark to have Aspen Process Economic Analyzer scan for errors before evaluation. Item Report Select which type of report you wish to display when generating an Item Report. HTML Item Report – mark to display the HTML Item Report, like the one shown on page 462, in the Main Window X406H X Capital Cost Report – mark to display the Capital Cost Report in Icarus Editor. Reporter Report – mark to display the Single Component Summary, exported from Aspen Icarus Reporter, in the Main Window. Display Save Window States – mark to have Aspen Process Economic Analyzer save the position of Project Explorer, the Main Window, the Palette, and the Properties Window, as well as selected columns on the List view. Unmark to have Aspen Process Economic Analyzer open with the default interface arrangement (shown on page 26). X407H X Display Aspen Capital Cost Estimator & Analyzer Choice Dialog on Aspen Process Economic Analyzer – mark to have Aspen Capital Cost Estimator ask you at startup whether to use Aspen Process Economic Analyzer and/or Analyzer in the Aspen Process Economic Analyzer environment. This option is included here because Preference selections (except for file locations) made in one product affects all other Aspen Icarus products in the AES suite. Show Report Group in Aspen Capital Cost Estimator – mark to have Aspen Capital Cost Estimator display Report Groups. Forms The Forms tab view provides options related to Component Specification and Installation Bulk forms. Display P&I Installation Bulks in Grid – mark to have Aspen Process Economic Analyzer display all items on the Installation Bulk specification forms for Pipe and Instrumentation. If you unmark the checkbox, Aspen Process Economic Analyzer allows you to select, when opening the form, the items to include. Use OK Button in Installation Bulks Form to Go to Main Component Form – mark to have Aspen Process Economic Analyzer return you to the main Component Specifications form when you click OK at an Installation Bulks form. Otherwise, clicking OK simply closes the Component specifications. 2 Getting Started 48 Save Component When Switching to Different Installation Bulk or Main Component Form – mark to have Aspen Process Economic Analyzer save the Component specifications when you switch to a different form on the Component’s Options menu. Backup The Backup tab view lets you select when backups are to be performed. You can select both options. Automatic Task Backup – mark to have Aspen Process Economic Analyzer perform a backup before executing major tasks, such as a project evaluation. Timed Backup (Interval, in minutes) – mark to have Aspen Process Economic Analyzer perform a backup at a specified interval. Specify the interval in the box provided. You can also select to either have Aspen Process Economic Analyzer overwrite the project backups or create unique backups. Overwrite Project Backups – mark to have Aspen Process Economic Analyzer overwrite the previous backup every time the program performs a backup. Unique Project Backups – mark to have Aspen Process Economic Analyzer retain previous backups by creating a unique backup each time. Depending on the frequency of backups (see task and timed backup options above), selecting Unique Project Backups could result in large amounts of disk space being consumed by backups. Process The Process tab view provides options for importing from an external project. Import Connected Streams – mark to include connected streams when importing an external project. Import Installation Bulks – mark to include installation bulks when importing an external project. The Process tab view also provides options for unsupported simulator models and custom model tool activation. Map Unsupported Models To Quoted Cost Item – mark to have Aspen Process Economic Analyzer map, by default, unsupported simulator models to quoted cost items. “Unsupported Models” refer to models not listed in the Project Component Map Specifications dialog box shown on page 80. Aspen Process Economic Analyzer does not recognize them and, therefore, cannot map them to Icarus project components. If this option is left unmarked, Aspen Process Economic Analyzer will not map unsupported models. As a result, a unit operation could appear disconnected in the Process Flow Diagram (PFD). X408H X Quoted cost items are not project components, but act as place markers to ensure that unit operations remain connected in the PFD. 2 Getting Started 49 Note that marking this option will not affect the mapping of supported simulator models. If a simulator model is listed in the Project Component Map Specification dialog box, then the specified mapping will be used. Further, if a simulator model is listed and has no default mapping (that is, Current Map List section is blank), then it is assumed that the user does not want to map such simulator models to any Icarus project components. For example, if this option is marked, a USER unit operation in Aspen Plus can be mapped to a quoted cost item if this option is marked. This ensures that the unit operation remains connected in the PFD. Activate Custom Model – mark to activate the Custom Model tool explained on pages 206 through 212. X409H X X410H X Use Automatic Mapping Selection when Available (Beta feature) – Mark to use the Mapping Selection feature explained in the section on 'Default and Simulator Data' Mapping. H1TU UTH Locations In the Locations tab view, you can select: Project Directories Add/remove alternate project directories and set the default project directory. See “Adding Project Directories” on page 51 for instructions. X41H X Other Locations Specifications To specify the location of various specification files and data: 1 Click an item in the list to display its description and location. 2 Click the Browse button to select a new location. Note: In some cases the description warns against changing the location. Note: Make sure to create the IP and MET subfolder structure when changing the source locations for library files that are units dependent (for example, Basis for Capital Cost, EML, UML, Custom Piping Specs, and so on). 2 Getting Started 50 Adding Project Directories Aspen Process Economic Analyzer comes set up with two project directories: ...\AspenTech\Economic Evaluation V7.0\data\My Econ_Process Projects ...\AspenTech\Economic Evaluation V7.0\data\Archives_Econ_Process These directories, by default,are the sole choices of project directory when opening or saving a new project, as well as the only directories displayed on the Palette’s Projects view. To add a project directory and set a new default 1 2 Getting Started On the Locations tab view of the Preferences dialog, click Add. 51 The Browse for Folder dialog box appears. 2 Select the folder you wish to add as an alternate directory and click OK. Aspen Process Economic Analyzer adds the directory to the Alternate Project Directories list. 3 To set an alternate project directory as the default, select it and click Set Default. Aspen Process Economic Analyzer displays a prompt asking you to confirm the change. 4 2 Getting Started Click Yes to set the new default. 52 If the old default location is not on the list of alternate project directories, Aspen Process Economic Analyzer displays another prompt asking if you wish to add it to the list. 5 Click Yes or No. Note: Adding the old default directory to the alternate project directory list lets you easily revert to it. 6 Click OK to save the changes to Preferences. Before the added project directory appears on the Create New Project dialog box and elsewhere, you will need to either restart Aspen Process Economic Analyzer or else right-click on the current project in the Palette and click refresh on the pop-up menu. Logging The Logging tab view is reserved for future releases, in which it will be used to help clients with Technical Support issues. It is not currently activated. 2 Getting Started 53 2 Getting Started 54 3 Defining the Project Basis The Project Basis defines specifications that pertain to the overall project scenario. These specifications influence the design and cost estimate by defining system defaults and environmental variables. Project Basis Specifications are accessed from the Project Basis view in Project Explorer. A red arrow on an icon indicates that you can right-click on the item to access a pop-up menu. 3 Defining the Project Basis 55 This chapter describes the different Project Basis specifications, as well as how to customize specification libraries. Project Properties Project Properties are initially specified when creating a new project. To access Project Properties: • Right-click on Project Properties in the main Project Basis folder, and then click Edit. The Project Properties dialog box appears. You cannot edit: • Project Name • Scenario Name • Units of Measure You can specify these only when creating a new project. You can edit the following: • Project Description: The description entered here appears as the Project Description on the Project Summary spreadsheet and as the Brief Description on the Executive Summary spreadsheet. The project description is shared by all scenarios that are under the project. The description can be up to 500 characters in length and can be comprised of letters, numbers, and punctuation. • Remarks: Any remarks entered will appear immediately after the Title Page of evaluation reports in Icarus Editor. Remarks can be up to 6,000 characters in length and can be comprised of letters, numbers, and 3 Defining the Project Basis 56 punctuation. Remarks might include, for example, the intended purpose of the estimate, executive summary of results, or an explanation of assumptions. General Project Data General Project Data is initially specified when creating a project. To access General Project Data: 1 Right-click on General Project Data in the main Project Basis folder. 2 In the menu that appears, click Edit. The Standard Basis Input File Specifications form appears. You cannot edit: • Units of Measure • Country Base • Currency Symbol These can only be specified when creating a new project. You can edit the following: 3 Defining the Project Basis 57 • Currency Conversion Rate: The number of currency units per one country base currency unit. This is for when you are using a currency other than that of the country base. • Project Title: Appears as the project title on reports in Aspen Icarus Reporter and Icarus Editor and appears as the Scenario Description on the Project Summary spreadsheet. • Estimate Class: Appears on the Title Page in Icarus Editor. Intended to indicate the purpose of specifications (for example, budget). • Job Number: Appears on the Title Page in Icarus Editor. • Prepared By: Appears at the top of reports generated by Aspen Icarus Reporter and on the Title Page in Icarus Editor. • Estimate Date: Appears immediately under the project title at the top of the Title Page in Icarus Editor. Reports generated by Aspen Icarus Reporter also include an Estimate Date; however, the Estimate Date shown in Aspen Icarus Reporter is the date on which the project evaluation was run. Importing old Standard basis files 1 Open your Aspen Icarus Project Evaluator Software. 2 Go to the Libraries tab. 3 Click Basis for Capital Costs. 4 Right-click either Inch-Pound or Metric. 5 Click IMPORT. The dialog that appears defaults to looking for the .D01 files for your Aspen Process Economic Analyzer project. 6 Browse to the Aspen Process Economic Analyzer project you want to import. 7 Click the Aspen Process Economic Analyzer project file to import. Your Aspen Process Economic Analyzer template (standard basis file) is now in the new Aspen Icarus Project Evaluator system. Basis for Capital Costs • The Basis for Capital Costs folder includes: • Units of measure customization. • General specs affecting capital and operating costs, including contingency (based on specified process description, process complexity, and project type) , process control, location, engineering start date, soil conditions, vessel design code, and level of instrumentation. • Workforce wage rates (for both the overall project and by craft), productivities, and workweek definition. • Indexing of material costs and man-hours by COA. 3 Defining the Project Basis 58 Input Units of Measure Customization Input Units of Measure Customization allows you to customize the units of measure that appear on specification forms. Input Units of Measure Customization can only be accessed from outside of the project in the Palette’s Libraries view. It does not appear in the Project Explorer’s Project Basis view. To customize input units of measure: 1 With no project open, expand the Basis for Capital Costs folder in the Palette’s Libraries view. Expand the appropriate units of measure basis folder – Inch-Pound or Metric. Right-click on one of the specification files and click Modify. Note: If you are modifying a file you will need to later select the file in the project. To do so, right-click on Basis for Capital Costs in the Project Explorer’s Project Basis view, click Select, and select the file. Aspen Process Economic Analyzer displays the Basis for Capital Costs library in Project Explorer. 2 In the Units of Measure Customization folder, right-click on Input and click Edit on the pop-up menu. The Input Units of Measure Specifications dialog box appears. 3 Defining the Project Basis 59 3 If, for example, you want to use CM/H (centimeters per hour) instead of M/H (meters per hour) to specify conveyor belt speed in your metric-basis project, click Velocity and Flow Rate and then click Modify. 4 On the Velocity and Flow Rate Units form, enter “CM/H” as the new unit name for M/H. Then enter the conversion factor between the two units in the Conversion field. In this example, the conversion factor between the two units is 100 because: 100 CM/H = 1 M/H. 5 Click OK to accept the modifications and return to the previous dialog box. 6 When finished modifying input units of measure, click Close. 3 Defining the Project Basis 60 Output (Reports) Units of Measure Customization Output (Reports) Units of Measure Customization allows you to customize the units of measure that appear on Capital Costs and other reports. To customize output units of measure 1 Right-click on Output (Reports) Units of Measure Customization in the Basis for Capital Costs folder in Project Explorer’s Project Basis view, and then click Edit on the pop-up menu. The Output Units of Measure Specifications dialog box appears. You can change the basis for all output units of measure by selecting a different basis in the Unit of Measure Basis section; however, note that this voids all previous customizations. 2 To customize only individual units, such as velocity and flow rate units, select the unit type and click Modify. Then, for each unit you wish to change, enter the new unit name and the conversion factor (between the old and new units). 3 Defining the Project Basis 61 In this example, centimeters per hour (CM/H) replaces meters per hour (M/H). A conversion factor of 100 has been entered because 100 CM/H = 1 M/H. 3 For example, if you want to use CM/H (centimeters per hour) instead of M/H (meters per hour) to specify conveyor belt speed in your metric-basis project, enter “CM/H” as the new unit name for M/H. Then, enter the conversion factor between the two units in the Conversion field. In this example, the conversion factor between the two units is 100 because 100 CM/H = 1 M/H. 4 Click OK to accept the modifications and return to the previous dialog box. 5 When finished modifying output units of measure, click Close. General Specs General Specs greatly affect the total capital and operating cost of the project. To access General Specs: 1 Right-click General Specs in the Project Basis view’s Basis for Capital Costs folder. 2 On the menu that appears, click Edit. menu. The section of the Standard Basis file containing General Specs appears in a specification form. 3 Defining the Project Basis 62 Process Description, Process Complexity and Project Type combine to generate contingency (as a percent of total project cost). They are interdependent, and the final value is a nonlinear combination of the individual contribution. As an example of the various rule-based deductions used, consider the selections made in the Standard Basis file pictured above: • Process Description: New and unproven process • Process Complexity: Highly complex • Project Type: Grass roots/Clear field Since the process is new and unproven, contingency value is made “high” compared to the base condition. Also, since the process complexity is high, the contingency is “raised” again. The Grass roots/Clear field project type “lowers” the contingency because of reduced site constraints. Note: You must clear the Contingency Percent field for the system to calculate the contingency based on your changes. Field Description Process Description Also drives the design allowances for all equipment whose material cost is systemgenerated. User-entered costs are not affected. A new and unproven process has a higher design allowance compared with a proven process. This is applied against all non-quoted equipment Process Complexity Used to adjust contingency. Highly complex implies high temperature/pressure and more 3 Defining the Project Basis 63 Field Description instrumentation and controllers (for example, batch), whereas simplicity implies offsites. Process Control You can provide either digital, analog or distributed control system for the project and the process control strategy is fixed with this choice. Project Information Project Location Adjusts the various location dependent cost fields based on the actual geographical location of the project site. The system calculates values such as freight (domestic and ocean), taxes/duties, wage rates and workforce productivities. Project Type Used to determine the configuration of the project’s electrical power distribution and process control systems. Contingency Percent This field will have the value of the contingency percentage calculated by the standard basis expert based on user specification of project information. This allows you to modify the value estimated by Aspen Process Economic Analyzer. This value represents: Construction Contingency Material Contingency Engineering Contingency Estimated Start Year/Month/Day of Basic Engineering These three fields show the year, month, and day that the basic engineering will begin. Refer to Icarus Reference, Chapter 31: Engineering, for a definition of engineering functions. Soil Conditions Around Site Specifies the nature of the soil most prevalent around the construction site. This impacts the development of all foundations, the amount of pilings developed, any excavation and trenching work items, and construction rental requirements. Icarus Reference, Chapter 19: Civil, provides soil type definitions. 3 Defining the Project Basis 64 Field Description Equipment Specification Pressure Vessel Design Code Specifies the design code used for pressure vessels design. The following design codes can be chosen: ASME = ASME code, Section VIII, Div 1 BS5500 = British code, BS5500 JIS = Japanese code, B8243 DIN = German Code, AD Merkblatt Vessel Diameter Specification Specifies the vessel dimension in the component specification form as inside diameter (ID) or outside diameter (OD). P and I Design Level Specifies the level of instrumentation provided for the equipment. The P and I may be standard instrumentation (STD) or highly instrumented (FULL). Refer to the Piping and Instrumentation Drawings for instrumentation on specific equipment. Data Affected by General Specs The following is a detailed description of the data affected by the General Specs and the magnitude of their effect depending on the different selections. • Domestic Freight (% of material) Specifies cost of domestic freight as a percentage of material costs. The value for this field depends on the project location selected in the standard basis. Domestic freight percentages for the different locations are: • o North America = 4 o South America = 5 o Central America = 5 o Europe = 1 o Asia = 1 o Africa = 4 o Australia = Ocean Freight (% of material) Specifies cost of ocean freight as a percentage of material costs. The value for this field depends on the project location selected in the standard basis. Ocean freight for the different locations is adjusted based on the percentage of plant material that can be purchased locally. The percent adjustments for the different locations are: 3 Defining the Project Basis o North America = 0 o South America = 8 o Central America = 5 65 o Europe = 0 o Asia = 0 o Africa = 8 o Australia = 12 The final value of the field is calculated by the following formula: O.F (%) = % Adjust * (100 - % material locally purchased) / 100 • Taxes/Duty (% of material) Specifies taxes as a percentage of total material costs. The value used in the capital cost evaluation depends on the project location chosen in the file. They are: • o North America = 6.25 o South America = 4.00 o Central America = 4.00 o Europe = 0.00 o Asia = 6.00 o Africa = 4.00 o Australia = 7.00 Contingency (%) Specifies allowance for contingencies as a percentage of the bare plant cost. This field depends on the selection made for the following fields in the standard basis file: o Process Description o Process Complexity o Project Type You must clear the Contingency Percent field for the system to calculate the contingency based on your changes. The following data defines the general design conditions to be applied to the entire project being estimated; this information is used to reflect the desired project design methodology. • Equipment Design Allowance (%) Specifies percent allowance for design changes for system developed equipment costs. The value depends on the selection made in the Process Description field. The following values are selected for the different project conditions: • o New and unproven process = 15 o New process = 10 o Redesigned process = 7 o Licensed process = 5 o Proven process = 3 Equipment Rotating Spares (%) Specifies a percentage of the purchase cost of all rotating equipment in the estimate to allow for spare rotors, seals and parts. The allowance for spares is developed based upon-0 purchased equipment cost values for pumps, 3 Defining the Project Basis 66 compressors, drivers and generators. The following value is chosen for the above field based on the project location: • o North America = 7 o South America = 10 o Central America = 10 o Europe = 7 o Asia = 10 o Africa = 15 o Australia = 7 Soil Condition at Site Specifies the soil type used to develop data for civil work throughout the project. Based on the soil type chosen, soil loading and soil density are selected. Icarus Reference, Chapter 19, provides a complete definition for all the soil types. Once the soil type is selected, the system automatically selects the type of piles used in the project. The following pile types will be selected: Soil Type Pile Type Soft clay Creosoted wood - 18-30 tons Firm clay Creosoted wood - 18-30 tons Wet sand Creosoted wood - 18-30 tons Sand+clay Precast concrete - 24-50 tons Dry sand Precast concrete - 24-50 tons Sand Precast concrete - 24-50 tons Gravel Steel h-pile - 60-170 tons Soft rock Steel h-pile - 60-170 tons Hardpan Steel h-pile - 60-170 tons Med-rock Steel h-pile - 60-170 tons Hard rock Steel h-pile - 60-170 tons Pile foundations are designated according to the country base default capacities and spacing. Pile foundations are provided for equipment and structures whose weight (including concrete) exceeds one-half the pile compression capacity. • Power Distribution The type of project is used to configure the electrical power distribution system inside Aspen Process Economic Analyzer. The power distribution specification generated by Aspen Process Economic Analyzer provides the means of designating MAIN and UNIT substations and the cabling between them Note that no transmission LINE is provided for any of the different choices of “Project Type.” Components Included Project Type 3 Defining the Project Basis MAIN Substation UNIT 67 Grass roots/Clear field Transformers, Switchgears MCC, SW Transformer Plant addition adjacent to existing plant Switchgear MCC Plant addition inside existing plant Switchgear MCC Plant addition suppressed infrastructure None Added None Added Plant Modifications / Revamps Switchgear MCC In addition, for plant modifications/revamps, the capital cost excludes cable costs related to connecting the main substation with the unit; in contrast, for the remaining project types, a default distance of 1,000 FEET [300 M] (excluding hook-up allowance) is used to cost the power distribution components. • Process Control Specifies the desired type of control scheme: Analog, DDCTL (Distributed Digital), or PLC (Programmable Logic Controllers) • Project Schedule Components Included Project Type Operator Center Control Center The system Grass roots/Clear field YES YES develops a Plant addition NO NO project schedule suppressed based upon the infrastructure estimate scope All others NO YES of work including dates and durations for design engineering, procurement, delivery of materials and equipment, site development and construction. The construction schedule is integrated with the cost estimate to provide the basis for estimation of schedule-dependent costs such as equipment rental requirements, field supervision and construction management. The schedule commences at the start of basic engineering, as indicated by the date for basic engineering in the standard basis file. In addition, the General Specs provide defaults for various general design conditions that control project design methodology. This in turn affects costs for equipment, material and manpower, and the overall project schedules. These defaults are not editable in Aspen Process Economic Analyzer. The following defaults (based on their major categories) are used by Aspen Process Economic Analyzer to convey specifications for the project design data: 3 Defining the Project Basis 68 Item Defaults Equipment Remote shop fabrication maximum dimensions: Maximum diameter: 14.5 FEET [4.5 M] Maximum length: 100 FEET [30 M] Maximum weight: 250 TONS [225 TON] Piping Pipe Fabrication: Remote shop fabricated piping Specifies the general method of pipe fabrication for the project. Civil Concrete Mix type: READY - Ready mix (purchased) Steel Steel finish type: PT – painted steel Project Schedule Start engineering phase: BASIC – Basic engineering phase Delivery Schedule Adjust (%): 100 Specifies an adjustment, as a percentage, to the schedule durations developed by the system for delivery of equipment items, bulk materials, control system. This adjustment applies to receipt of vendor data and fabricate/ship lead times. Construction Schedule Adjust (%):100 Specifies an adjustment, as a percentage, to the schedule durations developed by the system for all construction manpower. Bar Symbol: * Specifies the symbol to be used to print summary activity bars. Gap Symbol: - Specifies the symbol to print the gaps within activity bars. Critical path symbol: c Specifies the symbol to be used to print the critical path. User bar symbol: x 3 Defining the Project Basis 69 Symbol for printing user-defined bars on bar charts. Engineering Adjustment for Basic Engineering Phase % man-hour: 100 Engineering Adjustment for Detailed engineering Phase % man-hour: 100 Contracts (scope/definition) Contract number: 1 Adjustment of the duration of the basic engineering phase. A value less than 100% will shorten the duration. A value greater than 100% will increase the duration. Adjustment of the duration of detail engineering. A value less than 100% will shorten the duration. A value greater than 100% will increase the duration. Specifies the number used to reference this contract, its description, scope of effort and profile of indirects, overheads, fee, contingency, etc. Company title: PRIME CONTRACTOR Specifies the description of the contract. This description is used as the title in appropriate reports. Construction Workforce Construction Workforce specifications are divided into General Rates and Craft Rates. General Rates The General Wage Rates information globally sets wage rates and productivities for all crafts. To access: 1 Right-click on General Wage Rates in the Project Basis view’s Basis for Construction Workforce folder. 2 On the menu that appears, click Edit. 3 Defining the Project Basis 70 Aspen Process Economic Analyzer displays the Wage General Info specifications form in the Main Window. Descriptions of the General Wage Rate specifications follow. Field Description Number of shifts Number of shifts used during construction. If any premium pay is involved with second and third shift work (beyond overtime pay), such premium should be indicated by a properly averaged craft rate per shift. Productivity adjustment Specifies whether to use multi-shift /workweek adjustments or not. Indirects If wage rates are to be treated as all-inclusive, the indirects may be deleted for this workforce by specifying “-”. Selecting an all-in rate suppresses all construction indirects: fringes, burdens, small tools, construction rental equipment, etc. All Crafts Percent of Base Workforce reference base 3 Defining the Project Basis Enter B for system base. (Reference to a previously defined workforce number applies to Icarus 2000 only.) 71 Field Description Wage Rate percent of base Wage rates for all crafts as a percentage of reference base wage rates. Productivity percent of base Productivities for all crafts as a percentage of reference base wage rates. All Crafts Fixed Rates This input may be used to globally set the wage rates and productivities of all crafts in this workforce to fixed values. Wage rate all crafts Specifies the fixed wage rate (in the project currency) for all crafts in the workforce. See discussion in Icarus Reference. Productivity all Specifies the fixed productivity value for all crafts crafts in this workforce. See discussion in Icarus Reference. If no value is specified, the system defaults to 100%. Work week per Refer to the description of workforces in shift Icarus Reference for the effect of changing the work week and number of shifts upon productivity and job duration. The standard workweek plus overtime must not exceed 84 hours per week per shift. Standard work Specifies number of standard hours per week week per man per shift. Overtime Specifies number of overtime hours per week per man per shift. Overtime rate percent standard Specifies overtime pay expressed as a percentage of standard pay (for example, time and one half = 150%). General Craft Wages The general craft wages are for crafts that could appear in most crews and whose productivities and/or wage rates are dependent on the type of crew. Helper wage rate UK Base only. Specifies wage rate for craft help as a fixed rate to be used in all crews. Helper wage percent craft rate UK Base only. Specifies the wage rate for craft help as a percent of the principal craft in the crew. This value must be less than 100%. 3 Defining the Project Basis 72 Field Description Foreman wage Specifies the wage rate for foremen as a rate fixed rate to be used in all crews. Default: 110% of rate of highest paid craft in crew. Foreman wage Specifies the wage rate for foreman as a percent craft percent of the highest paid craft in crew. rate This value must be greater than or equal to 100%. Default: 110% of rate of highest paid craft in crew. Craft Rates Craft Rates set the wage rate and productivity individually for each craft. To access: 1 Right-click on Craft Rates in the Project Basis view’s Basis for Capital Costs\Construction Workforce folder. 2 On the menu that appears, click Edit. Aspen Process Economic Analyzer displays the Wage Rate Info specifications form in the Main Window. 3 To add multiple definitions to Craft Wage Rates, click the Add button on the button bar: 4 Use these fields to set the wage rate and productivity individually for each craft. Field Description Craft wages/prod. Wage rates and productivities may be assigned to individual crafts. Those 3 Defining the Project Basis 73 Field Description crafts not referenced are assigned wage rates and productivities specified in General Wage Rate or the system default values. Craft code Identifies the craft to which the following wage rate and productivity apply. The craft code must be an existing system craft code. Wage rate/mh Specifies the wage rate (in the project currency) for this craft for standard hours. Productivity Specifies the productivity of this craft as a percentage of the system’s base. (See discussion in Icarus Reference.) Indexing The Material and Man-hour specification forms in the Indexing folder allow you to manipulate the material and/or man-hour costs for process equipment and installation bulks. You can also adjust these indexes by location by using the Location specification form. For example, you could specify to increase the material costs associated with a type of process equipment. Indexing is used to tailor Aspen Process Economic Analyzer to mimic your work methods and costs. If your equipment costs for a category are consistently offset from Aspen Process Economic Analyzer’s values, use Indexing to correct that. To adjust the Material or Man-hour index 1 Right-click on Material or Man-hour and click Edit. 3 Defining the Project Basis 74 2 To adjust the index for all equipment or for all of one of the installation bulks, enter the index value in the box provided. For example, entering “200” in the Equipment box will double the material costs for all items under the equipment account group. To adjust the index for a sub-category, click the arrow-button in the box. This accesses a similar form listing sub-categories corresponding to the Code of Accounts (see Icarus Reference, Chapter 34, for a complete list). Adjustments to a sub-category override adjustments to the account-group. 3 Click OK to close the form and apply changes. To adjust by location 1 Right-click on Location and click Edit. 2 Type the location description. 3 Type the Code of Account (COA) to indicate the start of the COA range, or click the red arrow and then click Select by the subcategory on the COA Subcategory Selection window. 3 Defining the Project Basis 75 The Equipment COA Selection window appears. 4 Click Select again by the COA. The COA is entered on the form. 5 Do the same to indicate the end of the COA range. 3 Defining the Project Basis 76 6 Enter the amount to escalate material costs and/or the amount to escalate man-hour costs. 7 To escalate another range, click Add. 8 Click OK to close the form and apply changes. Process Design The Process Design specifications are used in Aspen Process Economic Analyzer projects that contain a simulator input. These specs allow Aspen Process Economic Analyzer to map simulator models into Icarus project components. For example, a distillation column model in a simulator may be mapped to a combination of equipment such as a double diameter tower, an air-cooler (for a condenser), a horizontal tank (for a reflux drum), a general service pump (for a reflux pump) and a thermosiphon reboiler. The Process Design Specifications indicate the default settings that the system uses for mapping all models of the same class. These specs can be customized in files and used in many projects. Simulator Type and Simulator File Name Simulator Type and Simulator File Name are described under Loading Simulator Data on page 143. X412H X Simulator Units of Measure Mapping Specs The Simulator Units of Measure Mapping Specs are used in mapping simulator units to Aspen Process Economic Analyzer units, serving as the cross-reference. To access: 1 Right-click on Simulator Units of Measure Mapping Specs in the Project Basis view’s Process Design folder. 2 On the menu that appears, click Edit. 3 Defining the Project Basis 77 The Units of Measure Specification dialog box appears. Note: Each simulator cross-reference UOM file contains a basis (which may be METRIC or I-P). The basis indicates the Aspen Process Economic Analyzer base units set to which simulator units will be converted. The left side of the screen displays the simulation output units. The right side of the screen displays the corresponding Aspen Process Economic Analyzer units. The conversion factors between the two units are entered in the lowercenter section of the screen. Aspen Process Economic Analyzer provides a set of common simulator units and their conversions to Aspen Process Economic Analyzer units. You can modify and/or add units to these files. Specifying the Mapping for a Simulator Unit To specify the mapping for a simulator unit: 1 Select the simulation unit from the Units Used list in the Simulation Output section. In the example below, the simulation unit is CM/HR (Centimeters/Hour). 2 Select the appropriate units category from Units Category list in the Aspen Process Economic Analyzer section. In the example below, the units category is Velocity. 3 Select the appropriate Aspen Process Economic Analyzer unit from Units list in the Aspen Process Economic Analyzer section. In the example below, the Aspen Process Economic Analyzer unit is M/H (Meters/Hour). 3 Defining the Project Basis 78 Note: If an equivalent Aspen Process Economic Analyzer unit is not found, select Miscellaneous as the Units Category and map the simulator unit to Other in the Units window. 4 Enter the conversion factor between the two units (the simulation unit and the Aspen Process Economic Analyzer unit) in the Conversion Factor box. In the example below, the conversion factor between 100 CM/HR = 1 M/H 5 Click Save to save the mapping. When a unit has been mapped and saved, a green box appears next to the simulation unit. A yellow box indicates the unit is not mapped. Deleting a Mapping To delete a mapping • Select the simulator unit; then click Delete. Removing a Unit To remove a particular unit from the simulation units list • Select the unit; then click Remove. 3 Defining the Project Basis 79 Adding a Unit To add a new unit to the list, enter the new unit symbol in the New Units to Add box in the Simulation Output section and click Add. Changes will not affect existing project components. Changing Existing Components To change existing components: 1 Unsize the item or unmap the items and then re-map and re-size. 2 Once all of the units have been specified, click OK to store and save the specifications. It is critical that all simulator units of measure be mapped into Aspen Process Economic Analyzer units. When the simulator output is loaded, Aspen Process Economic Analyzer identifies all units of measure in the file. Any units not mapped in the project’s current simulator cross-reference UOM specification are automatically added to the list and you are alerted to the need to define the mapping and re-load the file. You must correct this in order to continue without problems. Complete the steps above to specify the mapping for a simulator unit. Scroll through the Units Used list for any yellow-tagged units. Map all these, save the file, and re-load the simulator data. Project Component Map Specifications The Project Component Map Specifications dialog box contains a list of models for the selected simulator and a list of the corresponding Icarus project components to which the simulator models will map. To access: 1 Right-click Project Component Map Specifications in the Project Basis view’s Process Design folder. 2 On the menu that appears, click Edit. 3 Defining the Project Basis 80 Models that are mapped in the current file are marked with an asterisk (*). If no asterisk is present, then that model will not generate any project components when loaded, mapped, and sized. 3 Exclude simulator models from the mapping process by selecting the simulator item and then clicking Delete All Mappings. You can select a simulator item and review the mapping(s) for that item. To change one of the mappings: 1 Click an item in the Current Map List. 2 Click Delete One Mapping 3 Create a new mapping. To create a new mapping: • Click New Mapping; then select an appropriate Icarus project component. For simulator column models, an additional specification can be made. Since a column may be mapped to multiple pieces of equipment, Aspen Process Economic Analyzer requires an identification for each of these mappings. Refer to Mapping Simulator Models in Chapter 4 for tower/column configuration mapping identifications. Note: You can select in Preferences to have Aspen Process Economic Analyzer map unsupported simulator models (i.e., models not included in the list of simulator models on the Project Component Map Specifications dialog box) to quoted cost items. See page 49 for instructions. X413H 3 Defining the Project Basis X 81 Default Simulator Mapping Specs The following tables list models that are mapped to Aspen Process Economic Analyzer project components. Models that are not supported can be mapped to a quoted item if you mark “Map Unsupported Models To Quoted Cost Item” in Preferences, Process tab (see page 49). X41H X AspenTech’s Aspen Plus Map Specs Model Name Model Description Aspen Process Economic Analyzer Default CCD Countercurrent decanter Rotary drum filter CFUGE Centrifuge filter Centrifuge SOLID-BOWL COMPR Compressor/turbine Centrifugal gas compressor / Gas turbine with combustion chamber CRUSHER Solids crusher Jaw crusher CYCLONE Solid-gas cyclone Cyclone Dust collector DECANTER Liquid-liquid decanter Vertical vessel – process DISTL Shortcut distillation rating Single-diameter trayed tower DSTWU Shortcut distillation design Single-diameter trayed tower ESP Electrostatic precipitator Low voltage electrical precipitator FABFL Baghouse filter Cloth bay baghouse FILTER Continuous rotary vacuum Rotary drum filter FLASH2 Two-outlet flash Vertical vessel – process FLASH3 Three-outlet flash Vertical vessel – process FSPLIT Stream splitter HEATER Heater/cooler Floating head heat exchanger HEATX Two-stream heat exchanger Floating head heat exchanger HYCYC Solid-liquid hydrocyclone Water only cyclones - mineral PUMP Pump/hydraulic turbine Centrifugal single or multi-stage pump RADFRAC Rigorous fractionation Single-diameter trayed tower (column) Floating head heat exchanger (condenser) U-tube reboiler (reboiler) Horizontal drum (accumulator) Centrifugal single or multi-stage pump (reflux pump) PETROFAC 3 Defining the Project Basis Consists of 42 configurations. It has been confirmed that the following can be mapped to Aspen Single-diameter trayed tower (column) Floating head heat exchanger (condenser) U-tube reboiler (reboiler) Horizontal drum (accumulator) 82 Process Economic Analyzer: Centrifugal single or multi-stage pump (reflux pump) PREFLIF- preflash block with furnace, zero pumparounds and zero sidestrippers. Furnace block CDUIOF – crude block with furnace, three pumparounds and three sidestrippers. CDU 3 – vacuum block with two pumparounds and two sidestrippers. RBATCH Batch reactor Agitated Tank – enclosed, jacketed RCSTR Continuous stirred tank Agitated Tank – enclosed, reactor jacketed REQUIL Equilibrium reactor Agitated Tank – enclosed, jacketed RGIBBS Equilibrium reactorgibbs Agitated Tank – enclosed, energy jacketed minimization RPLUG Plug-flow reactor Single diameter packed tower RSTOIC Stoichiometer reactor Agitated Tank – enclosed, jacketed RYIELD Yield reactor Agitated Tank – enclosed, jacketed SCFRAC Short-cut distillation Single-diameter trayed tower SCREEN Wet or dry screen separator Vibrating system SWASH Single-stage solids washer Rotary drum filter VSCRUB Venturi scrubber Washer dust collector ChemCAD V Map Specs Model Model Description Aspen Process Economic Analyzer Default BAGH Baghouse filter Cloth bay baghouse dust collector COMP Adiabatic (isentropic) or polytopic Compression Centrifugal Axial Gas Compressor CFUG Basket centrifugal filter Atmospheric suspended basket centrifuge CRYS Crystallizer or melting by cooling/heating Batch vacuum crystallizer CSED Solid-wall basket centrifuge separating solids from liq slurry Solid bowl centrifuge CYCL Gas-solid cyclone separator Cyclone dust collector DRYE Dryer Direct rotary dryer EREA Equilibrium reactor Agitated tank reactor ESPT Electrostatic precipitator Low voltage electrical precipitator 3 Defining the Project Basis 83 FIRE Fired heater Floating head heat exchanger FLAS Multipurpose flash Vertical cylindrical vessel FLTR Vacuum or constant-pressure filter Rotary disk filter GIBS Gibbs reactor Agitated tank reactor HCYC Hydrocyclone Water cyclone (separation equipment) HTXR Heat exchanger Floating head heat exchanger KREA Kinetic reactor (plug flow or continuous stirred tank reactors) Agitated tank reactor LLVF Vapor/liquid/liquid flash Vertical cylindrical vessel MIXE Stream mixer (flash calculation at output pressure) Vertical cylindrical vessel PUMP Liquid pump (to increase pressure of liquid stream) Centrifugal pump REAC Stoichiometric reactor Agitated tank reactor SCDS Simultaneous correction rigorous fractionation (single column) Single diameter trayed tower Floating head heat exchanger (condenser) U-tube reboiler (reboiler) Horizontal drum (accumulator) Centrifugal single or multi-stage pump (reflux pump) SCRE Screen Single deck rectangular vibrating screen TOWR Inside/out rigorous fractionation (single column) Single diameter trayed tower Floating head heat exchanger (condenser) U-tube reboiler (reboiler) Horizontal drum (accumulator) Centrifugal single or multi-stage pump (reflux pump) WASH Washer Washer dust collector Hysim Map Specs Model Name Model Description Aspen Process Economic Analyzer Default BAG FILTER Baghouse filter Dust collector cloth bay COLUMN Distillation column Single-diameter trayed tower Floating head heat exchanger (condenser) U-tube reboiler (reboiler) Horizontal drum (accumulator) Centrifugal single or multistage pump (reflux pump) COMPRESSOR Compressor Centrifugal gas compressor CSTR Continuous stirred-tank Agitated Tank - enclosed, 3 Defining the Project Basis 84 jacketed CYCLONE Gas-solid separator Cyclone dust collector EXPANDER Expander Gas turbine FILTER Rotary drum filter Rotary drum filter HEATER Heater/cooler Floating head heat exchanger HEATEX Simple heat exchanger Floating head heat exchanger HYDROCYCLONE Solid-liquid hydrocyclone Water only cyclones - mineral separation PIPING Pipeline PLUG Plug-flow reactor Single-diameter packed tower and others PUMP Pump Centrifugal single or multi-stage pump RATEHEATEX Rigorous heat exchanger Floating head heat exchanger REQUI Equilibrium reactor Agitated Tank - enclosed, jacketed RGIBBS Gibbs-energy reactor Agitated Tank - enclosed, jacketed RSTOIC Stoichiometric reactor Agitated Tank - enclosed, jacketed SOLIDSEP Solids separator Cyclone dust collector HYSYS Map Specs Model Name Model Description Aspen Process Economic Analyzer Default AIR COOLER Air cooler Free standing or rack mounted air cooler BAG FILTER Baghouse filter Dust collector cloth bay COLUMN Distillation column Single-diameter trayed tower COMPRESSOR Compressor Centrifugal gas compressor CSTR Continuous stirredtank Agitated Tank – enclosed, jacketed CYCLONE Gas-solid separator Cyclone dust collector EXPANDER Expander Turbo expander FILTER Rotary drum filter Rotary drum filter HEATER Heater/Cooler Floating head heat exchanger HEATX Simple heat exchanger Floating head heat exchanger HYDROCYCLONE Solid-liquid hydrocyclone Water only cyclones – mineral separation PLUG Plug-flow reactor Single-diameter packed tower and others PUMP Pump Centrifugal single or multi-stage pump REQUI Equilibrium reactor Agitated Tank – enclosed, jacketed RGIBBS Gibbs-energy reactor Agitated Tank – enclosed, jacketed RSTOIC Stoichiometric reactor Agitated Tank – enclosed, jacketed 3 Defining the Project Basis 85 SEP Separator HT Drum – horizontal drum TANK Tank VT Storage – flat-bottom storage tank, optional roof SimSci's Pro/II with PROVISION SimSci’s Pro/II Map Specs Model Name Model Description Aspen Process Economic Analyzer Default CENTRIFUGE Centrifuge Solid bowl centrifuge COLUMN UNITS Distillation column Single-diameter trayed tower Floating head heat exchanger (condenser) U-tube reboiler (reboiler) Horizontal drum (accumulator) Centrifugal single or multi-stage pump (reflux pump) COMPRESSOR Compressor Centrifugal gas compressor CRYSTAL Crystalizer Oslo growth type crystalizer CSTR Continuous stirred tank Agitated Tank - enclosed, jacketed DECANTER Countercurrent decanter Rotary drum filter DEPRESSURE Non-steady-state depressure Vertical vessel - process DRYER Solids dryer Atmospheric tray dryer EXPANDER Expander Gas turbine FLASH FLASH Vertical vessel - process HEATEX Simple heat exchanger Floating head heat exchanger PLUG Plug-flow reactor Single diameter packed tower PUMP Pump Centrifugal single or multi-stage pump REACTOR Reactor Agitated Tank - enclosed, jacketed RIGHTEX Rigorous heat exchanger Floating head heat exchanger ROTDRUM Rotary drum filter Rotary drum filter SHORTCUT Distillation column Single-diameter trayed tower Design Criteria After the simulator model is loaded into Aspen Process Economic Analyzer, mapping and sizing of the items can be performed. If an item is already sized inside the simulator, the sizing parameters are automatically brought into Aspen Process Economic Analyzer and used. Items not sized by the simulator can be sized following the instructions in Chapter 6. In addition to process information obtained from the simulator, certain design specifications may be required before sizing can be accomplished. 3 Defining the Project Basis 86 Aspen Process Economic Analyzer’s Sizing Expert uses design values based on the user-defined field values on specification forms in the Design Criteria sub-folder. The values on these forms provide the basis for developing design specifications from operating conditions for all equipment to be sized. You can enter design conditions (design pressure and temperature) for all equipment (using the Common form) and also enter design conditions for types of equipment. (Conditions entered on the equipment type forms override those on the Common form). Common Design pressure and temperature entered on the Common specifications form applies to all equipment except equipment for which you have separately specified these design conditions. • Design Pressure Click on the Design Pressure field to open the Design Pressure Specifications form. The specifications form lets you specify rules for calculating the design pressure based on the range in which the operating pressure falls. The design pressure is calculated from the operating pressure using the formula shown on the form. You can modify the pressure limit (upper and lower limit) as well as parameters A and B. 3 Defining the Project Basis 87 Note: In earlier versions of Aspen Process Economic Analyzer, the “Design Pressure – Multiplier” field was used. This field has now been replaced by the Design Pressure Specifications form. If projects created using these earlier versions are opened, then the parameters A and B are automatically adjusted based on the multiplier value specified. This ensures that old projects can be carried over using the same design criteria. • Design Temperature Click on the Design Temperature field to open the Design Temperature Specifications form. The specifications form lets you specify rules for calculating the design temperature based on the range in which the operating temperature falls. The design pressure is calculated from the operating temperature using the formula shown on the form. You can modify the temperature ranges (upper and lower limit) as well as parameters A and B. Note: In earlier versions of Aspen Process Economic Analyzer, the “Design Temperature - Increase” field was used. This field has now been replaced by the Design Temperature Specifications form. If projects created using these earlier versions are opened, then the parameters A and B are automatically adjusted based on the multiplier value specified. Pumps In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for pumps: X415H • X Pump Overdesign Factor The pump overdesign factor is used by Aspen Process Economic Analyzer to increase the volumetric throughput of the pump and the power requirement of the pump. The total volumetric flow rate calculated from the simulator information is multiplied by the value provided in this field to estimate the design flow rate for the equipment. For example: 3 Defining the Project Basis o Operation flow rate: 250 GPM o Pump overdesign factor: 1.1 88 o Calculated design capacity: 250 X 1.1 = 275 GPM Compressors In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for compressors: X416H • X Driver Type Specifies the driver type used for compressors. The default value is “None.” The selections are NONE, GAS ENGINE, MOTOR, TURBINE. Heat Exchangers In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for heat exchangers: X417H • X Launch MUSE MUSE™ performs detailed simulation of multi-stream plate-fin heat exchangers made from brazed aluminum, stainless steel or titanium. A valid MUSE version 3.3 license is required to use this feature. Select “Yes” to launch MUSE during interactive sizing of plate fin heat exchangers. Select “No” to run MUSE in the silent mode. • Furnace Fractional Efficiency The furnace duty obtained from the simulator is the absorbed duty. Total fired duty is obtained by dividing the absorbed duty by fractional efficiency. This value should be <1.0. • Fuel Heating Value The Lower Heating Value (LHV) used to estimate the fuel consumption by fired furnaces. • Air Cooler Inlet Temperature This field represents the default value that shall be used as the inlet air temperature in the case of Air Coolers. • Air Cooler Exit Temperature Air Cooler Exit Temperature is used when estimating the surface area of air cooled heat exchangers. The value given in this field is used as the exit temperature for the air cooler. If the field is empty or has value of 0.0, then the Sizing Expert assigns the exit air temperature value to be 10.0 DEG F greater than the inlet air temperature. For example, if the Air Cooler Inlet Temperature is 77.0 DEG F and you do not enter the Air Cooler Exit Temperature, Aspen Process Economic Analyzer uses 87.0 DEG F as the default value. • Apply 2/3 Rule for Design Pressure In the design of shell and tube heat exchangers, design engineers sometimes apply the 2/3rd rule in calculating the design pressure. As per P 3 Defining the Project Basis P 89 ASME heat exchanger code, if the design pressure of the lower-pressure side (either tube or shell) is at least 2/3rd the design pressure on the high-pressure side, then overpressure in the high-pressure side will not result in rupture in the lower-pressure side (provided relief devices have been properly sized). When specified, the 2/3 rule will increase the design pressure of the low pressure side to at least 67% of the design pressure of the high pressure side, even when the operating pressure on the low pressure side could result in a lower design pressure as per the Design Pressure field. • Heat Exchanger Area Minimum Overdesign Factor The calculated heat transfer area is multiplied by the value given in the field. The mechanical design is performed for the final heat transfer area. For example: o Calculated surface area = 1000 SF o Heat Exchanger Area Minimum Overdesign Factor = 1.1 o Surface area used for mechanical design: 1000 X 1.1 = 1100 SF Note: The final surface area in general is greater than the calculated value because of mechanical considerations. Towers In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria on the Towers form (applies to all towers): X418H • X Bottom Sump Height (For Trayed and Packed Towers) For both trayed and packed towers, extra height in addition to that required for separation is provided at the bottom for liquid level and reboiler return. The value in this field is added to the calculated height of the tower. • R/R-Minimum (For SHORTCUT model in Pro/II) The SimSci simulator shortcut distillation model calculates the number of theoretical stages required for different ratios of operating reflux ratio (R) to minimum reflux ratio (R-Minimum). The number of stages should be available in the simulator report for the ratio chosen. • Vapor Disengagement Height (For Trayed and Packed Towers) For both trayed and packed towers, extra height in addition to that required for separation is provided at the top for vapor disengagement before passing to the condenser. The value in this field is added to the calculated height of the tower. 3 Defining the Project Basis 90 Packed Towers In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for packed towers: X419H • X Packing Type Two types of packings, random and structured, are used in packed towers. The type of packing affects the flood point pressure drop estimation and the packing efficiency (HETP) value. The value in this field is used by the Sizing Expert in the calculation of the tower diameter and height. • Packing Factor for Packings Packing factor is used in the Kister and Gill correlation to estimate pressure drop at the flood point. Once the pressure drop is known, the flood velocity is calculated using the latest versions of the generalized pressure drop correlation (GPDC) charts for both the random and structured packings. • Packed Tower Derating Factor With certain systems, traditional flooding equations consistently predict higher flood points than those actually experienced. To allow for such discrepancies, an empirical derating factor (< 1.0) is applied. The derating factor is multiplied by the predicted flood vapor load or liquid load obtained from the traditional equation to obtain the actual or derated flood load for the given system. The derating factors are often vaguely related to the foaming tendency of the system. The higher the foaming tendency, the lower the derating factor. If you do not enter a value, Aspen Process Economic Analyzer uses 1.0 as the derating factor. • Packed Tower Flooding Factor Packed towers are usually designed for 70 to 80 percent of the flood point velocity. This allows a sufficient margin for uncertainties associated with the flood point concept and prediction and to keep the design point away from the region at which efficiency rapidly diminishes (just below the flood point). The Sizing Expert uses the default value specified if the user-provided value is not available. • HETP The concept of HETP (height equivalent of a theoretical plate) enables comparison of efficiency between packed and plate columns. Because there are only a few variables that significantly affect HETP and due to the unreliability of even the best mass transfer models, rules of thumb for HETP successfully compete with the mass transfer models. For the packing types available in Aspen Process Economic Analyzer (given in the Icarus Reference), Aspen Process Economic Analyzer estimates the HETP value based on the packing shape, dimensions and type of material. If a user-provided value is available, then the Sizing 3 Defining the Project Basis 91 Expert uses the value in the above field for calculating the height of the packed tower. • Packed Section Height The value represents the height of each packed section and is used in the design of packed towers to estimate the number of packed sections. • Surface Area Per Unit Volume Higher specific surface areas (surface area per unit volume) increases vapor-liquid contact area and therefore, efficiency. For structured packings, Aspen Process Economic Analyzer determines this value empirically and uses it in estimating HETP if you have not already specified an HETP value. A default value of 75 SF/CF is used in the absence of a user-entered value. Trayed Towers In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for trayed towers: X420H • X Trayed Tower Flooding Factor Flooding is the condition where pressure drop across a tray is sufficient to cause the dynamic liquid head to be equivalent to the tray spacing plus the weir height. At this point, the liquid backup in the downcomer is just at the point of overflowing the weir on the plate above. When this happens, the column fills with a foamy liquid and becomes inoperable. The flood factor is the fractional velocity approach to flooding, i.e., (Actual Vapor Velocity)/(Vapor velocity at the point of flooding). The Sizing Expert uses the default value specified if the user-provided value is not available. • Foaming Tendency Vapor disengagement is easy in non-foaming, low-pressure systems. However, vapor disengagement from downcomer liquid in foaming systems is difficult as the liquid hangs on to the entrained vapor. Sufficient residence time must be provided in the downcomer to allow adequate disengagement of vapor from the descending liquid. Industrial practice has created a guideline for the mum downcomer velocity of clear liquids based on their foaming tendency. The following values for the downcomer liquid velocity are used based on the choice for the above field. Downcomer Liquid Velocity, (FPS) Tray Spacing, INCHES Foaming Tendency 18 24 30 Low 0.4 – 0.5 0.5 – 0.6 0.6 – 0.7 Moderate 0.3 – 0.4 0.4 – 0.5 0.5 - 0.6 3 Defining the Project Basis 92 High 0.2 – 0.25 0.2 – 0.25 0.2 - 0.3 With certain systems, traditional flooding equations consistently predict higher flood points than those actually experienced. To allow for such discrepancies, an empirical derating factor (< 1.0) is applied. The derating factor is multiplied by the predicted flood vapor load or liquid load obtained from the traditional equation to obtain the actual or derated flood load for the given system. The trayed derating factors are often related to the foaming tendency of the system. The higher the foaming tendency, the lower the derating factor. If the user-specified value is not available, a derating factor is selected based on the value of foaming tendency. The default value for foaming tendency is Moderate. • Trayed Tower Derating Factor With certain systems, traditional flooding equations consistently predict higher flood points than those actually experienced. To allow for such a discrepancy, an empirical derating factor (< 1.0) is applied. The derating factor is multiplied by the predicted flood vapor load or liquid load obtained from the traditional equation to obtain the actual or derated flood load for the given system. The derating factors are often vaguely related to the foaming tendency of the system. The higher the foaming tendency, the lower the derating factor. If the user-provided value is not available, or the value 0.0 is entered in the field, then the derating factor is selected based on the foaming tendency of the liquids in the column. • Relative Volatility of Key Components The number of theoretical stages for a trayed tower is obtained from the simulator report. The actual number of trays is calculated by using the tray efficiency value provided by the user in the design criteria file. However, if the field is empty or has a 0.0 value, the tray efficiency for the separation is estimated by using the correlation of relative volatility of key components with tray efficiency. The O’Connell correlation is used to estimate the overall tray efficiency. • Tray Efficiency Overall column efficiency is defined by: E_oc = N_t/ N_a where: N_t = Number of theoretical stages required for the separation minus the sum of theoretical stages provided by the reboiler, condenser, and intermediate heat exchangers. N_a = Number of actual trays in the column. Several empirical correlations are available in the literature. Also, rigorous theoretical predictions based on gas and liquid film resistances are available to assist in predicting the tray efficiency. 3 Defining the Project Basis 93 If the user specification is not available for the field, then the value is estimated using empirical correlations from the literature. Configurations Towers Use this form to specify design criteria for tower configurations. Vessels In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria on the Vessels form (applies to all process vessels): X421H • X Residence Time The amount of liquid holdup in the vessel is estimated by the liquid volumetric flow through a vessel in a specified amount of time. The vessel volume divided by volumetric flow rate is defined as the residence time for the vessel. For example: • o Liquid flow through the vessel: 100 CFM o Residence time: 5 MIN o Calculated liquid volume in the vessel: 100 CFM X 5 = 500 CF. Process Vessel Height to Diameter Ratio (For Vertical and Horizontal Vessel Design) Aspen Process Economic Analyzer defaults for this field are used if the field is empty or has the value of “0.0.” The Aspen Process Economic Analyzer defaults depend on the operating conditions for the vessel. Based on the operating pressure of the vessel obtained from the simulator report, the following values are used: Pressure (PSIA) 0 – 250 250 – 500 > 500 Process Vessel Height to Diameter Ratio 3 4 5 For example: Vessel operation pressure: <250 PSIA Diameter: 6 FEET Calculated vessel height: 6 X 3 = 18 FEET Residence time overrides Process Vessel Height to Diameter Ratio. • Minimum Vessel Diameter The Minimum Vessel Diameter field is used if the vessel diameter calculated by the sizing routines is less than this value. • Vapor/Liquid Separator Sizing Method When sizing vertical and horizontal vapor liquid separators, Aspen Process Economic Analyzer computes the maximum allowable vapor velocity using the method selected in this field. o 3 Defining the Project Basis Liquid Entrainment Method: 94 This is an empirical correlation developed by Watkins and is a function of vapor and liquid densities, and the parameter Kv, which itself is a polynomial function of vapor and liquid flows and densities. o Particle size separation method: This method estimates the disengagement velocity of the liquid droplet in the continuous vapor phase. The design velocity is determined as a percentage of the disengagement velocity. • Average Liquid Particle Diameter (For particle size separation method) This field specifies the default average liquid droplet diameter. This value is used in the design of horizontal and vertical vessels by the particle size separation method (which can be selected in the Vapor/Liquid Separator Sizing Method field right above this field). • Design Factor Multiplier for Disengagement Velocity (For particle size separation method) This field is used in the calculation of the maximum allowable design velocity, which is a percentage of the disengagement velocity. For example: • o Disengagement velocity : 10 FEET/SECOND o Design factor multiplier for disengagement velocity: 0.5 o Maximum allowable design velocity: 10 X 0.5 = 5 FEET/SECOND Separation Factor (For liquid entrainment method) In the liquid entrainment method, the separation factor is used to determine the maximum allowable vapor velocity. The separation factor is either entered by the user in this field or computed by Aspen Process Economic Analyzer using the relation described in the vessel sizing design procedure. Agitated Vessels In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for agitated vessels: X42H • X Agitator Type The various types of agitators that can be chosen for design are described in the Icarus Reference. The type of agitator selected determines the default driver power and impeller speed. This is used to estimate the agitation requirements in tanks. Storage Vessels In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for storage vessels: X423H • X Number of Holding Days 3 Defining the Project Basis 95 Storage vessel sizing is determined by estimating the volume of liquid required for a certain period of operation. Aspen Process Economic Analyzer uses this field to determine the liquid volume stored in the vessel. For example: • o Inlet flow rate: 500 CF per day. o Number of holding days: 30 (specified by user). o Liquid volume inside the storage vessel: 500 X 30 = 1,500 CF. Holding Hours in a Day Storage vessel sizing is determined by estimating the volume of liquid required for a certain period of operation. Aspen Process Economic Analyzer uses this field to determine the liquid volume required per day. For example: • o Inlet flow rate: 500 CFH. o Holding Hours in a Day: 24 (specified by user). o Final volume per day : 500 X 24 = 12,000 CF/day. Storage Vessel Height to Diameter Ratio Once the volume of the storage vessel is determined based on the process fluid flow rate and design conditions, the actual dimensions (height and diameter) of the equipment must be estimated. You can specify the dimensional requirements of the equipment using this field. A default is used if the field is empty or has value 0.0. The default depends on the operating conditions for the vessel. • Vapor Free Space (% of Total Storage Vessel Volume) A percent volume of the sized vessel in excess of the required liquid volume. Horizontal Vessels In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for horizontal vessels: X42H • X Vapor Area /Cross-Sectional Area Once Aspen Process Economic Analyzer calculates the maximum vapor velocity, the velocity and flow rate are used to determine the vapor space required. The vapor space is then divided by the vapor area /crosssectional area to get the total required cross-sectional area. The process vessel height to diameter ratio overrides this field. • Separation Factor Multiplier For horizontal vessels, the separation factor is normally higher under similar operating conditions than for vertical vessels. Therefore, the calculated separation factor is multiplied by the separation factor multiplier. • Minimum Boot Length 3 Defining the Project Basis 96 When horizontal vessels are used for three phase separations, the heavy second liquid phase is removed in the drip leg situated at the bottom of the vessel. • Minimum Boot Diameter This field represents diameter of the boot leg which is designed to remove the heavy second liquid. • Boot Leg Liquid Velocity The bootleg cross-sectional area is estimated using the liquid velocity field specified in this field and the process vessel height to diameter ratio. Vertical Vessels In addition to entering design pressure and temperature (see instructions under Common, page 87), you can enter the following design criteria for vertical vessels: X425H • X Minimum Disengagement Height This is the height from the liquid level to the mist eliminator. • Minimum Height Above the Mist Eliminator Used in the calculation of the total vessel height. • Height of Mist Eliminator Height of mist eliminator section. • Minimum Ht. Btw Low and High Liquid Level Taps The liquid level based on residence time should meet this minimum specification. (Field is at bottom of form, not in Vertical Vessels section.) • Ht. Btw Inlet Nozzle and High Liquid Level Tap Represents the height between the inlet nozzle (center line) and the high liquid level tap. (Field is at bottom of form, not in Vertical Vessels section.) • Ht. Btw Low Liquid Level Tap and Tangent Line Represents the height between the low liquid level tap and the tangent line. (Field is at bottom of form, not in Vertical Vessels section.) Miscellaneous • Vibrating Screen Feed Material This field specifies the solid material type used by solids handling equipment. The material type affects the screen unit capacity which is defined as the amount of solids (TPH) flowing through one square foot of screen cloth based on material, having 6 to 8% moisture, screen cloth having 50% or more open area; 85% screen efficiency. Based on the choice made for this field and the screen opening size, the screen unit capacity is estimated. The following choices are available for this field: 3 Defining the Project Basis o Sand and Gravel o Limestone/Crushed Stones 97 • o Coal o Cinders o Coke o Wood Cyclone Inlet Linear Velocity In case of cyclones, the sizing program assumes a default linear velocity of 150 FPS. You can enter a different velocity here. Configurations Flash Use this form to specify design criteria for flash configurations. Utility Specifications Most chemical processes require heating or cooling process utility fluids to operate. In many cases, the choice of which utilities are used plays an important role in determining the total project cost by defining heat transfer equipment sizing. In addition, utility costs form an important part of the operating costs of the plant. In the design of heat exchangers and reboilers, Aspen Process Economic Analyzer permits you to select appropriate process utility fluids for the application. You can select utility fluids from the list already present in Aspen Process Economic Analyzer or can create your own based on utility fluid classes allowed by Aspen Process Economic Analyzer. Once the utility resource for the equipment is selected either by you or by the Sizing Expert, then an actual utility process stream is created for the equipment. The utility stream contains the amount of utility used by the equipment. During the operating cost evaluation, Aspen Process Economic Analyzer processes all the utility streams connected to the equipment to determine the utility cost for every utility resource used in the project. You can override these selections by a combination of disabling/enabling appropriate utilities and re-mapping and re-sizing the equipment items. Alternately, you can specify the desired utility in the interactive Sizing Expert. This method is available even if the utility has been disabled. To modify or create a utility stream: 1 Right-click on Utility Specifications in the Project Basis view’s Process Design folder. 2 On the menu that appears, click Edit. 3 Defining the Project Basis 98 The Develop Utility Specifications dialog box appears. Aspen Process Economic Analyzer provides 11 default utility streams resources: Cooling Water High Temp Heating Oil * Low Temp Heating Oil ** Refrigerant – Ethane Refrigerant - Ethylene Refrigerant - Freon 12 Refrigerant - Propane Refrigerant - Propylene Steam @165 PSI Steam @100 PSI Steam @400 PSI * High temperature heating oil has the properties of DOWTHERM A. ** Low temperature heating oil has the properties of DOWTHERM E. To modify an existing utility stream: • Highlight it on the Modify Existing Stream list and click Modify. To create a new utility stream: 1 Click Create in the Option section. 2 In the Create New Utility Stream section, type the name and select one of the following fluid classes: 3 Defining the Project Basis 99 High Temp Heating Oil * Low Temp Heating Oil ** Refrigerant – Ethane Refrigerant – Ethylene Refrigerant – Freon 12 Refrigerant – Propane Refrigerant – Propylene Refrigerant 50 Utility Steam Water * High temperature heating oil has the properties of DOWTHERM A. ** Low temperature heating oil has the properties of DOWTHERM E. 3 Click Create. 4 Enter or modify the specifications on the Utility Specifications form. The form contains the following fields: Description: Describes the utility fluid resource in the sizing report generated by Aspen Process Economic Analyzer. Also, the field value is used to represent the utility fluid usage and its related cost on the Project Summary investment analysis spreadsheet (PROJSUM.ICS). Fluid: Determines the type of utility fluid described by the current specification. The fluid class is used to determine the heat transfer coefficient, fouling tendency and related thermal and transport properties used by Sizing Expert. Design Temperature Specifies the temperature, which will be considered in the estimation of the design temperature for the process equipment carrying the utility fluid. Design Pressure: 3 Defining the Project Basis 100 Specifies the pressure, which will be considered in the estimation of the design pressure for the process equipment carrying the utility fluid. Inlet temperature: Provides the inlet temperature for the utility fluid. Exit temperature: Provides the exit temperature condition for the utility fluid. Pressure: Provides the operating pressure for the utility fluid. Energy transfer per unit mass: Specifies the amount of energy provided or removed by the utility fluid over the specified temperature range. The value in this field is used to estimate the amount of utility required for the given process conditions. Unit Cost: Provides the cost value used to estimate the utility cost for the project. Unit Cost Units: Provides the units for the value provided in the unit cost field. When you specify a new utility fluid resource, all the information on the specification form must be provided; otherwise, the Sizing Expert will not be able to use the utility fluid resource properly. Using the utility specification form, you can specify a maximum of 20 utility fluids. If different utility fluid resource was used by simulation, then it is added to the utility resource in Aspen Process Economic Analyzer. Utility type: Describes the usage of the utility fluid. Select either Heat source or Heat sink. Click OK when done entering the utility specifications. Investment Analysis Investment Parameters To specify parameters required for investment analysis: 1 Right-click Investment Parameters in the Project Basis view’s Investment Analysis folder. 3 Defining the Project Basis 101 2 On the menu that appears, click Edit. Aspen Process Economic Analyzer displays the Investment Parameters in the Main Window. A description of the parameters follows. General Investment Parameters Period Description This field allows you to enter text indicating the name/description of a period. The period is defined in “Number of Weeks per Period.” The period description is used in the display of some of the results in the spreadsheets. 3 Defining the Project Basis 102 Number of Weeks per Period The period used for investment analysis is defined in terms of number of weeks. Number of Periods for Analysis The number of periods to include in the cashflow and other project totals and calculations. Tax Rate The tax rate for investment analysis, in terms of percent per period, is used to calculate the percentage of earnings before taxes that must be paid to the government. Desired Rate of Return The desired rate of return, in percent per period, for the investment. Economic Life of Project This field indicates the length of time in terms of periods over which capital costs will be depreciated. Salvage Value (Percent of Initial Capital Cost) This number indicates the approximate worth of capital costs at the end of the Economic Life of Project. The number is expressed as a percent of initial capital cost. Depreciation Method There are four depreciation methods allowed in Aspen Process Economic Analyzer. The description of each follows: Straight Line — The straight line method is used most commonly. In this method, the Salvage Value is subtracted from the Total Project Cost. This result is then divided by the Economic Life of Project, so that the project is depreciated evenly over its economic life. Sum of the Digits — When this method is used, the Depreciation Expense decreases during each period of the Economic Life of Project. Therefore, the highest value for the depreciation occurs in the first period and decreases every period thereafter. The sum of the digits multiplier is n/((N(N+1))/2), where N is the Economic amount is the Total Project Cost less its Salvage Value. For the duration of the project’s economic life, this factor is multiplied by the depreciable amount. Double Declining (Balance) — When this method is used, the project is depreciated in geometric increments. The multiplier for the first period is 2/N, where N is the Economic Life of Project. For the second period the depreciation rate, D2, is (1-D1)D1 where D1 is 2/N. For the third period, the depreciation rate, D3, is (1-D1)D2. For the fourth period, the depreciation rate is (1-D1)D3. These factors are multiplied by the Total Project Cost. This 3 Defining the Project Basis 103 process (multiplying the factor by the capital cost) continues until the Straight Line Method produces a higher value for the depreciation. When the Straight Line Method produces a higher value, this higher value is used for the remaining depreciation calculations. Accelerated Cost Recovery System (ACRS) — The ACRS approach assumes that operations begin during the second half of the first period and stop during the first half of the last period. Therefore, as a result of the two halfperiods (one at the beginning and one at the end of the operating cycle), it takes 6 periods to depreciate a project which has an Economic Life of 5 periods. The ACRS adapts the Double Declining Balance Method to the halflife system. The depreciation rate for the first period, D1, is 2/N, where N is the Economic Life of Project. However, the half-life convention reduces this factor to 1/N. For the second period the depreciation rate, D2, is D1(1-1/ N). For the third period the depreciation rate, D3, is D1(1-1/N-D2). This process (multiplying the factor by the Total Project Cost continues until the Straight Line Method produces a higher value for the depreciation. When the Straight Line Method produces a higher value, this higher value is used for the remaining depreciation calculations. Escalation Parameters Project Capital Escalation This number indicates the rate at which project capital expenses may increase expressed in percent per period. If the addition of Engineer-Procure-Construct (EPC) period and start-up period is greater than one whole period, Project Capital Escalation is used to escalate the capital expenses for periods beyond the first period. Products Escalation This is the rate at which the sales revenue from products of the facility is to be escalated (increased) in terms of percent per period. Raw Material Escalation This is the rate at which the raw material costs of the facility are to be escalated (increased) in terms of percent per period. Operating and Maintenance Labor Escalation This is the rate at which the operating and maintenance costs of the facility are to be escalated (increased) in terms of percent per period. The operating labor costs include operators per shift and supervisory costs. Utilities Escalation User-entered percentages reflecting the anticipated utility price increase each period. 3 Defining the Project Basis 104 Project Capital Parameter Working Capital Percentage The working capital expressed as a percentage of total capital expense per period indicates the amount required to operate the facility until the revenue from product sales is sufficient to cover costs. It includes current assets such as cash, accounts receivable and inventories. When the facility starts producing revenue, this cost item can be covered by the product sales. Operating Costs Parameters Operating Supplies This field indicates the cost of miscellaneous items that are required in order to run the plant in terms of cost per period. Laboratory Charges This is a cost per period indicating the cost of having product analyzed each period. Operating Charges This includes operating supplies and laboratory charges. It is specified as a percentage of the operating labor costs. (If you specify a value for either “Operating Supplies” or “Laboratory Charges”, the system will add the two entered values and calculate the percentage of Operating Labor Costs. (This is done for compatibility with earlier releases of the system.) Plant Overhead This field consists of charges during production for services, facilities, payroll overhead, etc. This number is specified as a percent of operating labor and maintenance costs. This number should not be used for the construction of the facility, only for operation after start-up. G and A Expenses This represents general and administrative costs incurred during production such as administrative salaries/expenses, R&D, product distribution and sales costs. Specify this number as a percentage of subtotal operating costs. Facility Operation Parameters Facility Type This field defines the facility type. The following types are currently available: Chemical Processing Facility Food Processing Facility Oil Refining Facility 3 Defining the Project Basis 105 Petrochemical Processing Facility Pharmaceutical Facility Pulp and/or Paper Processing Facility Specialty Chemical Processing Facility (A specialty chemical is defined as a chemical which is produced in low quantity and has a usually high price per unit.) The type of facility affects the number of operators/shift and maintenance costs of facility equipment. Operating Mode This refers to the operating mode of the facility. The available options are: Continuous Processing - 24 Hours/Day Continuous Processing - Less than 24 Hours/Day Batch Processing - 24 Hours/Day Batch Processing - 1 Batch per Shift Batch Processing - More than 1 Batch per Shift Intermittent Processing - 24 Hours/Day Intermittent Processing - Less than 24 Hours/Day The operating mode of the facility affects the number of operators/shift and maintenance costs of facility equipment. Length of Start-up Period After the facility has been constructed (i.e., gone through engineering, procurement and construction), the plant must go through the owner’s startup period until it starts producing the product to be sold. This period is referred to as Length of Start-up Period in weeks and is added into the EPC duration. Operating Hours per Period This field refers to the number of hours per period that the plant will be operating. Process Fluids Process Fluids indicate the types of fluids involved in the process. The selection affects operating and maintenance costs. The selections are: Liquids Liquids and Gases Liquids and Solids Liquids, Gases, and Solids Gases 3 Defining the Project Basis 106 Gases and Solids Solids Operating Unit Costs To specify operating unit costs: 1 Right-click on Operating Unit Costs in the Project Basis view’s Investment Analysis folder. 2 On the menu that appears, click Edit. Aspen Process Economic Analyzer displays the Operating Unit Costs in the Main Window. The Operating Unit Cost form specifies Labor Unit Costs and non-heat transfer Utility Unit Costs. Labor Unit Costs are given for Operators and Supervisors. The total cost of operating labor is calculated by: Determining the total number of operators and supervisors necessary to run the facility for a certain number of hours. Adjusting that number for the number of hours the facility operates per period. Multiplying that number by the respective Labor Unit Costs and adding them together. 3 Defining the Project Basis 107 Labor Unit Costs Operator The loaded wage rate paid for operating the facility in terms of the cost per operator per hour. Operator labor includes labor that is associated with operating the facility. Supervisor The loaded wage rate paid for supervision in terms of the cost per supervisor per hour. Supervision includes all labor associated with overseeing personnel who operate the facility. Utility Unit Costs The non-heat transfer utility unit costs are also specified in this file as “over the fence” costs. Utilities used for process heating and cooling are given in the Utility Specifications File. Electricity The unit cost per KWH of electricity used for the facility. Potable Water The potable water unit cost per MMGAL or MB used for the plant. Fuel The fuel unit cost per MMBTH or MEGAWH used for the plant. Instrument Air The instrument air unit cost per KCF or MB. Raw Material Specifications An investment analysis conducted on any process needs to provide an accurate figure for total project expenditure. Since operating costs are usually a large part of this cost, it is important to accurately account for all raw materials consumed in the process. Aspen Process Economic Analyzer lets you identify simulator streams as raw materials for the process. The raw material costs will be directly placed in the PROJSUM.ICS spreadsheet for use in cash flow analyses. To develop raw material specifications: 1 Right-click Raw Material Specifications in the Project Basis view’s Investment Analysis folder. 2 On the menu that appears, click Edit. 3 Defining the Project Basis 108 The Develop Raw Material Specifications dialog box appears. 3 In the Option section, click the Create option button. 4 In the Create New Stream section, type a name for the stream. 5 Select the Basis and the Phase for the stream. 6 Click Create. The Raw Material Specifications dialog box appears. The following input information is required in order to estimate the raw material costs during the evaluation of the operating costs for the project: Process Stream (or “none” if user-defined); Rate (do not specify a rate if a process stream is selected); and Cost Per Unit. 3 Defining the Project Basis 109 In addition to the above minimum information, you have to specify certain field values for the raw material fluid program to estimate the raw material rate necessary for the cost estimate. If you specify “none” in the Process Stream field, then the value for the Rate field must be specified in the appropriate units. If you specify a process stream, then the program determines the raw material rate in the desired Specification Basis and units. You can specify a maximum of 150 raw material streams. The Raw Material Specifications form contains the following fields: Description The value you provide in this field will be used to describe the raw material in the Project Summary investment analyses spreadsheet (PROJSUM.ICS) Specification Basis This field describes the raw material properties from the following list: Mass, Gas Mass, Liquid Mass, Solid Volume, Gas Volume, Liquid Volume, Solid Energy Process Stream This field provides a list of fluid streams present in the current project. You can select any stream to represent the raw material. Also, there is a provision in Aspen Process Economic Analyzer for you to provide actual value for the raw material rate if none of the process streams represent the raw materials for the project. In this case, you must specify the field value as “none.” Rate This field gives the total rate of raw materials consumed for the process in the desired rate units. When a new raw material fluid is specified, Aspen Process Economic Analyzer checks whether enough information has been specified to estimate the raw material cost. Rate Units This field describes the flow rate units for the current raw material. The choices available for the field vary with the selection made for Specification Basis and your choice of Base UOM: Specification Basis I-P METRIC Mass, Gas LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH 3 Defining the Project Basis 110 Mass, Liquid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Mass, Solid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Volume, Gas GPH M3/H MMGAL/H L/S CFH KCFH Volume, Liquid GPH M3/H MMGAL/H L/S CFH KCFH Volume, Solid GPH M3/H MMGAL/H L/S CFH KCFH Energy BTU/H W MMBTU/H KW MEGAW CAL/H Unit Cost This field provides the cost value per unit mass, volume or energy used to estimate the raw material cost for the project. 7 When you are done entering raw material specifications, click OK. The new stream appears in the Existing Stream list on the Develop Raw Materials Specifications dialog box. You can enter a maximum of 150 raw material streams using this dialog box. When done, click Close. Product Specifications An investment analysis conducted on any process needs to include an accurate figure for the project’s total revenue. In order to do so, it is very important to accurately account for all the products obtained from the process. Aspen Process Economic Analyzer allows you to identify simulation streams as product materials for the process. Once the simulation stream is defined, Aspen Process Economic Analyzer determines the necessary amount of product materials generated based on the information provided in the product material specification file. The product material costs are directly placed in the PROJSUM.ICS spreadsheet, where they are used for further cashflow analyses. 3 Defining the Project Basis 111 To develop product specifications: 1 Right-click Product Specifications in the Project Basis view’s Investment Analysis folder. 2 On the menu that appears, click Edit. The Develop Product Specifications dialog box appears. 3 Select the Create check box in the Options section. 4 Enter a new stream name, select a basis and phase. 5 Click Create. The Product Specifications form appears. 3 Defining the Project Basis 112 The following input information is needed for Aspen Process Economic Analyzer to estimate the product material costs during the evaluation of the operating costs for the project: Description The value specified in this field is used to describe the product material fluid in the investment analyses spreadsheet (PROJSUM.ICS). Specification Basis This field describes the product material properties from the following list: Mass, Gas Mass, Liquid Mass, Solid Volume, Gas Volume, Liquid Volume, Solid Energy Process Stream This field provides a list of streams present in the current project. You can select any of the streams to represent the product material. Also, there is a provision in Aspen Process Economic Analyzer for providing an actual value for the product material rate if none of the process streams represent the product materials for the project. In this case, you must specify the field value as “none.” Rate This field defines the total rate of product materials obtained for the process in the desired rate units. Do not enter a value if you have specified a process stream. When a new product material is specified, Aspen Process Economic Analyzer checks whether the minimum information necessary to estimate the product material cost has been specified. The following minimum information must be present before Aspen Process Economic Analyzer can proceed with the estimate. Rate Units This field describes the flow rate units for the current product material. The choices available for the field vary with the selection made for Specification Basis and your choice of Base UOM: Specification Basis I-P METRIC Mass, Gas LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH 3 Defining the Project Basis 113 Specification Basis I-P METRIC Mass, Liquid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Mass, Solid LB/H KG/H KLB/H MEGAG/H MLB/H TON/H TPH Volume, Gas GPH M3/H MMGAL/H L/S CFH KCFH Volume, Liquid GPH M3/H MMGAL/H L/S CFH KCFH Volume, Solid GPH M3/H MMGAL/H L/S CFH KCFH Energy BTU/H W MMBTU/H KW MEGAW CAL/H Unit Cost The field provides the cost value used to estimate the product material cost for the project. 6 When you are done entering product specifications, click OK. The new stream appears in the Existing Stream list on the Develop Product Specifications dialog box. You can enter a maximum of 150 product material streams using this dialog box. When done, click Close. Developing Streams After opening a project, new streams can be developed. You have the option to develop completely new streams or use an existing stream as a base. When an existing stream is used as a base, the new stream can be either copied from the existing stream (Absolute Basis mode) or copied from and linked dynamically to the existing stream (Relative Basis mode). To develop streams: 1 Right-click Streams in the Project Basis view’s main folder (at the bottom). 3 Defining the Project Basis 114 2 On the menu that appears, click Edit.. The Develop Streams dialog box appears. Viewing or Modifying an Existing Stream 3 To view or modify an existing stream, select the stream on the Modify tab view. You may need to use the scrollbar(s) to locate a stream if a large number of streams exist in the project. With the desired stream highlighted, click Modify to have the stream information displayed in a specifications form. 3 Defining the Project Basis 115 The functions of the six buttons on the Develop Stream specifications form are explained below: Click To do this: OK Perform a check on the information currently present in the Develop Stream specifications form to ensure that all information needed to specify the stream is completed. Aspen Process Economic Analyzer generates error messages indicating missing data. Generate estimates for any specifications not entered. Save the information in the Develop Stream specifications form. The Develop Stream specifications form closes and the Develop Streams dialog box re-appears. Apply Same as clicking OK, but does not exit the Develop Stream specifications form. This allows you to review the estimates and revise the data. Update Same as clicking Apply, except that if the Primary Fluid Component, the Temperature, and/or the Pressure were changed, then all the physical properties of the stream will be estimated using these new values. Cancel Exit the Develop Stream specifications form without making checks and does not save or change any information in the database. Reset Reset the information in the Develop Stream specifications form to the values previously saved into the database. Any changes have been made since opening the form will be lost. Mixture Define a stream as a mixture. Opens the Mixture Information dialog box discussed below. Most Develop Stream specifications need no further explanation. Those that do are described below. Primary Fluid Component One of the most important specifications in this form is Primary Fluid Component, which is classifies the chemical components of a stream. The 3 Defining the Project Basis 116 fluid selected here is used as the basis for any properties that are unavailable and need to be estimated to complete the specifications for the stream. The available general fluid classifications are: y Alcohol y Medium Hydrocarbon Liquid y Aromatic Liquid y Miscellaneous Inorganic Liquid y Halogenated Gas y Miscellaneous Organic Gas y Heavy Hydrocarbon Liquid y Organic Acid y Hydrocarbon Gas y Very Heavy Hydrocarbon Liquid y Inorganic Gas y Solid y Light Hydrocarbon Liquid The following pure components are also available for selection as the Primary Fluid Component of a stream: y Acetic Acid y Glycerol y Phosphoric Acid y Ammonia y Hydrogen y Propane y Argon y Isopropyl Alcohol y Propanol y Carbon Monoxide y Methane y Propylene y Carbon Dioxide y Methanol y Steam y Ethane y N-Butanol y Sulfuric Acid y Ethanol y Nitric Acid y Toluene y Ethyl Benzene y Nitrogen y Water y Ethylene y Oxygen If the Primary Fluid Component is specified, the other needed information will be filled in with default values. This feature is only apparent when no temperature or pressure is entered into the Develop Stream specifications form and the Primary Fluid Component is changed. After changing the Primary Fluid Component, either press Enter or click on another field and the default values will be loaded. If either the pressure or temperature value is changed from the default value, clicking OK, Apply, or Update will estimate the properties at the new condition(s). Base Stream The Base Stream field contains the name of the stream on which the displayed stream was based. This cannot be changed. If the name begins with the character “$”, the stream was created using Absolute Basis and the stream name following this character is that of the parent stream. A stream created using Absolute Basis uses the data from the parent stream; however, if the parent steam’s data changes afterward, the Absolute Basis stream is not updated. If the value begins with the character “@”, the stream was created using the Relative Basis and the stream name following this character is that of the parent stream. A stream created using Relative Basis is updated when its parent stream’s data changes. 3 Defining the Project Basis 117 Description Select information from the menu to describe the particular stream. For example, you can indicate the source component of the stream (for example, From Pump P-103) or tag it with one of the available utility stream names. Mass Flow The Mass Flow fields are used to determine the phase of the stream. For instance, if the stream has only Liquid Mass Flow specified, the stream is totally liquid; therefore, it will have no vapor properties estimated for it. The reverse is true for a case with only a Vapor Mass Flow specified. For cases with both types of flow, all properties will be estimated and the Primary Fluid Component will belong to the phase of the largest mass flow. Note: Aspen Process Economic Analyzer automatically calculates Total Mass Flow from the individual mass flow values. Density The Density fields are required information. Thus, if a particular phase has a mass flow rate specified, then the corresponding density must also be specified. Clicking Update will estimate any required density fields based on the flow rate, except in the case of Solid Mass Density. It is recommended that you enter a Liquid Mass Density if one is available. Mixture Specs Dialog Box Clicking Mixture on the Develop Stream specifications form accesses the Mixture Specs dialog box. After you click Apply, Aspen Process Economic Analyzer normalizes the Fraction values to total a sum of one. The values shown above would change into the values shown on the next page. 3 Defining the Project Basis 118 The mixture information specified in this dialog box is used to estimate properties as a mixture of the specified composition. If no mixture information is present, the stream is assumed to be pure Primary Fluid Component. The fraction information can be entered on either a Mass or Mole Fraction Basis, as specified in the Fraction Basis section. The Cancel and Reset buttons behave in a similar manner as their respective buttons on the Develop Stream specifications form. The OK and Apply buttons also behave in a similar manner as their respective buttons on the Develop Stream specifications form, except the checking is different. Here, a check is made to ensure that the fractions have a total sum of one. If not, the values are normalized to give a total sum of one, as indicated below. The check also combines duplicate entries into one entry by combining the two fraction specifications. After the check is done, the components are sorted in order of decreasing fractional amount, as shown above. When you click OK, Aspen Process Economic Analyzer loads into the specifications form the name of the fluid with the highest fraction and the properties of the mixture generated from the contributions of the individual components. Estimation of Utility Usage and Resulting Costs in Aspen Process Economic Analyzer Utility usage estimation is based on the stream information. All the streams that are present in the project are taken into consideration for the estimation of the utility usage for the project. This includes all utility streams, userdefined streams, simulator streams, and pre-map Streams. The Description field on the Develop Stream spreadsheet can be used to designate streams as utilities. If the Description field for a stream exactly matches (exact text characters and spaces) the Description field for any utility resource as given on the Utility Specifications spreadsheet, then that stream is included in the utility usage calculation. If you change the description field of any of the 3 Defining the Project Basis 119 simulator or pre-map streams, then the new description you provided is used for this calculation. Also, stream connectivity information is used to identify the nature of the stream. If the stream is being generated then it is considered to be revenue for the project, and if it is being consumed it is considered an expense. (Note: Streams that are connected at both ends to process equipments are ignored in estimating the utility usage costs. Also, utility streams that have a zero unit cost do not show up in the final report.) User-defined streams that are not connected to any equipment (do not show up in the PFD) are considered as input streams, i.e., consumption. System-generated utility streams are included in the utility usage calculation as long as they are connected to equipment. A case where they would be disconnected would be if you manually disconnect these streams or if the equipment to which these streams are connected is deleted. Notes to Analyzer Utility Model (AUM) Users: Cooling Water utility resources that need to be accounted in the Analyzer Utility Model (AUM) should be named as either Cooling Water or Cooling Water xx where xx can be two digits ranging from 01 to 99, for example, Cooling Water 01. User-created utility resources that do not adhere to this format (for example, CW, Sea Water, Cooling Water o3) will not be identified as cooling water streams and will be excluded from AUM's cooling water analysis. Cooling water streams that are not associated with any equipment, will be assigned to the Area with the maximum cooling water flow rate. For areas assigned to two or more circuits, the collected unassigned cooling water flow rate will be assigned to the first area in the circuit handling the largest circuit flow rate. Cooling water can either be bought or be made. If it is to be made, the dew point of ambient air added to the lower model limit for the approach gradient will determine the lowest possible deliverable temperature. To ensure that your specified cooling water utility resource streams can be made, review the limits for the two cooling water models (CTWCOOLING and CTWPACKAGED). Stream Connectivity Process streams are “connected” to project components in a real way. You can see this in the Process Flow Diagram (PFD) that you can display after loading and mapping simulator blocks. Each stream has a Source end and a Sink end. The Source end connects to an Outlet port on a component and the Sink end to an Inlet as depicted below: 3 Defining the Project Basis 120 In the PFD view, when you Edit Connectivity (see page 175) for the Sink end of a stream and move the mouse over a component, only Inlet port(s) turn green, thereby indicating their availability for making a connection to a Sink end. X426H X The same concept also carries into the Interactive Sizing form (see page 219). Only streams whose Sink ends are not connected are listed in the pulldown for any Inlet. This explains why the Inlet and Outlet pulldowns will include different streams. X427H X Since the connectivity in the PFD and the Interactive Sizing form are two ways of looking at the same information, Aspen Process Economic Analyzer tracks your changes and synchronizes them in both views. Thus, if you change the connectivity in one view, Aspen Process Economic Analyzer automatically changes it in the other view. When you first map and size components, the streams in the simulator will be connected to the project components and the underlying process conditions of those streams are available for further use. For example, you may create new streams based on the properties of any stream, connected or not, then use these new streams as Sources/Sinks for connecting new components (you might do this to set up spares). You may also add a New Mapping to an item already mapped and the newly mapped and sized item utilizes the underlying stream properties. Creating A New Stream Streams can be created from scratch or by using a base stream. To create a stream from scratch: 1 Go to the Create tab view on the Develop Streams dialog box. Without selecting a stream from the Base Streams list, click Create. (The Basis selection will not matter.) The Create Stream dialog box appears. 3 Defining the Project Basis 121 2 Enter a name for the new stream in the Create Stream dialog box. This name must not be the same as any existing streams in the project. 3 Click OK. The Develop Stream specifications form appears. Note: See page 116 and 116 for descriptions of the buttons and fields on this form. X428H X X429H X Enter values for the new stream. See page 116 for descriptions of the different fields. X430H 4 X When done, click OK. To create a stream based on an existing stream: 1 On the Create tab view on the Develop Streams dialog box, click the stream to be used as the base. 3 Defining the Project Basis 122 Select the Basis mode. If the Basis mode is Relative, the data from the two streams will be linked so that when the base stream is changed the new stream will inherit these changes. If the Basis mode is Absolute, the data from the base stream is copied to the new stream at the time the new stream is created. Changes in a base stream will not affect a new stream created via Absolute basis. 2 Click Create. The Create Stream dialog box appears. 3 Enter a name for the new stream in the Create Stream window. This name must not be the same as any existing streams in the project. Click OK. Aspen Process Economic Analyzer displays the specifications form for the newly created stream. The data is that of the Base Stream. Data appears gray (dimmed) to indicate that it is relative to a referenced Base Stream. 3 Defining the Project Basis 123 Note: See pages 116 and 116 for descriptions of the buttons and fields on this form. X431H X X432H X Even in a Relative Stream, you may override any value with a manual entry. If you do so, the text turns black, indicating that that value is absolute and therefore no longer references a Base Stream. 4 Make modifications to the data and click OK. Deleting a Stream Note: Only user-added streams and streams added by the Sizing Expert as utilities can be deleted. To delete a stream: 1 At the Delete tab view, select the stream to be deleted. You may need to use the scrollbars to locate a stream if a large number of streams exist in the currently opened project. 3 Defining the Project Basis 124 2 Click Delete. A dialog box will appear asking for confirmation of the delete action. 3 Click OK to delete the stream. – or – Click Cancel to retain the stream. Specification Libraries The default specifications are derived from files that you can access, when outside of a project, from the Palette’s Libraries view. It includes specification files for the following: • Basis for Capital Costs 3 Defining the Project Basis 125 • Cost Libraries (see Chapter 7, “Developing and Using Cost Libraries”) • Design Criteria • Investment Parameters • Operating Unit Costs • Product Specifications • Project Component Map Specifications • Raw Material Specifications • Simulator Units of Measure Mapping Specs • Utility Specifications When you create a project scenario, Aspen Process Economic Analyzer selects the specification file to use based upon the selected units of measure basis. However, you can right-click on any of the above Project Basis specification categories in Project Explorer, click Select on the pop-up menu, and select a different file from which to derive the default specifications. Customizing Specification Libraries When no project is open, you can create your own specification files or edit existing files. Then, when in a project, you can select your specification files. For example, if you frequently created project scenarios that used the same design basis, you could create a Basis for Capital Costs specification file with those design basis specifications. Then you could just select this file, instead of entering the specifications every time. If, after making modifications to your libraries, you wish to revert to the original libraries, you can copy or import the copy of the installed libraries provided in the following folder: …\AspenTech\Economic Evaluation V7.0\Program\Sys\Libraries Creating a File To create a specification file: 1 With no project open, go to the Libraries tab view in the Palette and expand the desired specification category. 2 Except for Investment Parameters and Project Component Map Specifications, right-click on the units of measure basis folder – Inch-Pound or Metric. For Investment Parameters, right-click on the Investment Parameters folder. For Project Component Map Specifications, right-click on the simulator type folder. 3 On the pop-up menu, click New. The New [Specification Category] dialog box appears. 3 Defining the Project Basis 126 4 Enter a file name and, if desired, a file description. 5 Click OK. Aspen Process Economic Analyzer creates the file and displays the specifications in a separate window. 6 Edit the specifications just as in a project. 7 When you are done, close the specifications window. If a library file is open, you cannot access another library file or open a project. See page 129 for instructions on selecting the newly created specification file to use in a project. X43H X Modifying a File To modify an existing specification file: 1 Right-click on it in the Palette (Libraries view). 2 On the menu that appears, click Modify. Importing a File You can import specification files from elsewhere on your computer or network. To import a file: 1 In the Palette (Libraries view), expand the library to which you wish to import a file. 2 Except for Investment Parameters and Project Component Map Specifications, right-click on the units of measure basis folder – Inch-Pound or Metric. For Investment Parameters, right-click on the Investment Parameters folder. For Project Component Map Specifications, right-click on the simulator type folder. 3 On the pop-up menu, click Import. 4 In the Select a File for Import dialog box, locate the file and then click Open. 3 Defining the Project Basis 127 The file is copied to the appropriate sub-folder. Duplicating a File To duplicate a file: 1 In the Palette (Libraries view), right-click on the file you wish to duplicate, and then click Duplicate on the pop-up menu. 2 Enter a file name and description (optional) for the new file. 3 Click OK. Aspen Process Economic Analyzer creates the file and displays the specifications in a separate window. 4 Edit the specifications just as in a project. 5 When you are done, close the specifications window. If a library file is open, you cannot access another library file or open a project. Deleting a File To delete a specification file: • In the Palette (Libraries view), right-click on the file to be deleted, and then click Delete on the pop-up menu. 3 Defining the Project Basis 128 Note: You cannot delete files named Default, only modify them. Selecting to Use a Different Specification File After creating a new specification file, you still need to select it in Project Explorer for Analyzer to use its specifications. To select a specification file: 1 In Project Explorer (Project Basis view), right-click on the specification category for which you wish to select a new file. On the pop-up menu, click Select. Aspen Process Economic Analyzer displays a dialog box listing the files available for the selected category. 2 Select a new file from which to derive default specifications and click OK. Changing File Directory Location If you decide to store specification library files in a directory other than the default, move the default files to the new location and recreate the same subfolder arrangement. Otherwise, Icarus will generate an error when you point to the new location. 3 Defining the Project Basis 129 3 Defining the Project Basis 130 4 Loading and Mapping Simulation Data Overview If the process you wish to evaluate in Aspen Process Economic Analyzer is based on a simulator file report from a process simulator software program, the first step, after creating a project scenario and defining the Design Basis, is to load and map simulation data. Aspen Process Economic Analyzer supports reports from the following simulators: • AspenTech’s AspenPlus Version 12.1 or higher • Chemstations’ ChemCAD for Windows Version 5.3.2 • HYSIM Version STD/C.271 • HYSYS Version 2.4.1 • SimSci’s PRO/II with PROVISION Version 5.61 • Pacific Simulation’s WINGEMS 2.0 • WinSim’s DESIGN II for Windows Version 8.17 Preparing Simulation Reports For Aspen Process Economic Analyzer to load the simulation data, an appropriate ASCII output report needs to be generated from the simulator. Most simulators describe the various steps needed to generate ASCII reports. This section provides additional procedures to generate reports in an Analyzer-compatible format. The procedures provided here start with the default report generation options. If changes have been made from the default report generation options, then it may be necessary to change them back to the default settings for creating an output report for Aspen Process Economic Analyzer. 4 Loading and Mapping Simulation Data 131 AspenPlus Report Generation AspenPlus provides a template containing the property sets that a project needs in order to generate an output report for Aspen Process Economic Analyzer. Note: If you use the template, the following component specification, if entered in AspenPlus, must be re-entered in Aspen Process Economic Analyzer: Block - CCD STAGE EFFICIENCY To use the template: 1 Open the project in AspenPlus. 2 On the File menu, click Import. 3 Navigate to: x:\Program Files\AspenTech\Economic Evaluation V7.0\Data\Load\ Note: This is the default path; it may differ depending on where you installed Aspen Icarus. 4 Depending on the simulation units of measure, select the appropriate simulator directory (for example, AspenPlus) and then the corresponding template (.apt) file. To create the required property steps in Aspen Plus without using a template: 1 On the Data menu, click Properties. This will open the data browser to the property specifications. 2 In the data browser tree structure, open the folder Prop-Sets located in the Properties folder. 3 Click New to create a new property set. 4 Type a name for the property set or use the default name. 5 Click OK. 6 In the Substream field, select All. 7 Scroll down the list of available properties, clicking those you wish to select. To start the scroll window, click in a physical properties cell: o MASSVFRA o MASSSFRA o MASSFLMX o VOLFLMX o MASSFLOW o TEMP o PRES o MWMX 4 Loading and Mapping Simulation Data 132 The specifications for this property set are complete as indicated by the check mark displayed on the tree view of the data browser. 8 Click the Prop-Sets folder. You will see the property set you just created in the object manager and the status should be Input Complete. 9 Create the second property set by once again clicking New. 10 Type a name for the property set or use the default name. 11 Click OK. 12 Click the Qualifiers tab. 13 In the Phase cell, click Total. 14 Click the Properties tab. 15 In the Substream field, click ALL. 16 Now click the Units cell corresponding to the CPMX property and pick either of the following units: o KJ/KG-K -oro BTU/LB-R The specifications for this property set are complete. 17 Click the Prop-Sets folder. The newly created property set will appear in the object manager with an input complete status. 18 Create the final property set needed by Aspen Process Economic Analyzer by clicking New. 19 Type a name for the property set, or use the default name. 20 Click OK. 21 Click the Qualifiers tab. 22 In the Phase cell, click Vapor. 23 Click the Properties tab. 24 Select the following properties for this property set: o VOLFLMX o MASSFLMX o KMX o MUMX o CPMX o MWMX 25 Now click the Units cell corresponding to the CPMX property and pick either of the following units: o KJ/KG-K -oro BTU/LB-R The creation of property sets is complete. Now these property sets must be specified for use in the generation of a report. 4 Loading and Mapping Simulation Data 133 To specify these property sets for use in report generation: 1 If the Setup folder is not already expanded, expand it by clicking on the plus sign next to the folder symbol. 2 Click Report Options. 3 Click the Stream tab. 4 Click the Property Sets button. 5 Move the three property sets you just created to the Selected property sets box. 6 Click the > button to move them to the Selected property sets box. 7 Click Close. The specifications required for loading an AspenPlus report file are now complete. You can close the data browser window. After running the simulation, you must create an output report. To create an output report: 1 On the File menu, click Export. 2 In the Save As dialog box, use the drop-down menu to select Report Files (*.rep) or XML files (*.xml). 3 Type a file name or accept the default value. 4 Click Save. This will create the ASCII report file needed to load into Aspen Process Economic Analyzer with the name given above. Note: The order on any of the tower models must be set to TOP-DOWN in order for the tray information to get loaded into Aspen Process Economic Analyzer correctly. This is the default setting. Aspen Plus Utilities If a unit operation block has a utility specified, the utility resource specifications and usage data will be transferred into Aspen Process Economic Analyzer. After loading the simulator data, a preference screen will appear. Specify any missing data for the Aspen Plus utilities in order for the Aspen Plus utility to be properly handled. The Aspen Plus utilities will appear as new utility resources. The appropriate project components will use the specified utility resource, based on the Aspen Plus utility used in the simulation. A message box will appear if utility resources are modified or deleted from the Aspen Plus simulation prior to a reload of data into Aspen Process Economic Analyzer. You can choose to delete the old imported Aspen Plus utility resources in Aspen Process Economic Analyzer, or just add/update existing imported utilities in Aspen Plus. 4 Loading and Mapping Simulation Data 134 AspenPlus – Aspen Process Economic Analyzer Simulator link A link from AspenPlus to Aspen Process Economic Analyzer allows you to load changes into Aspen Process Economic Analyzer when simulation settings are changed in AspenPlus. To load process simulator data through the Aspen Icarus link into a new Aspen Process Economic Analyzer project scenario: 1 Run the simulation in AspenPlus. 2 On the File menu, click Send To and click Aspen Icarus. When the prompt appears, the Aspen Process Economic Analyzer project name will be designated to be the name of the simulation file from AspenPlus. AspenPlus will designate the scenario name. If the scenario name is changed, any future attempts to run the link for the same project will result in a new Aspen Process Economic Analyzer project being created. It is recommended that the scenario name designated by AspenPlus be left as it is for maximum usability. 3 Click OK. The Project Properties dialog box appears. 4 Specify the Project Description, Remarks, and the Units of Measure. 5 Click OK. The Input Units of Measure Specifications dialog box appears. 6 Verify the Input Units of Measure Specifications; then click OK. The General Project Data dialog box appears. 7 Verify the General Project Data; then click OK. Aspen Process Economic Analyzer displays a prompt to load the Simulator Data. 8 Click OK. If the simulation has specified units that are undefined, a prompt will appear to do so. Define all AspenPlus units with those available in Aspen Process Economic Analyzer. To load process simulator data through the Aspen Icarus link into an existing project scenario: 1 Run the simulation in AspenPlus 2 On the File menu, click Send To and click Aspen Icarus. Aspen Process Economic Analyzer displays a prompt to load simulator data. 3 Click OK. Because all other project basis settings have been specified, mapping and sizing can be performed at this time. 4 Loading and Mapping Simulation Data 135 ChemCAD Report Generation These instructions apply to both ChemCAD for Windows, Version 5.3.2, and for previous versions of ChemCAD. The specifications are the same for all versions. 1 On the main menu, on the Output menu, click Report. Note: In ChemCAD for Windows, just click the Output menu from the menu bar. 2 Specify the following for report options: • Select Streams • Print All Streams: Y Note: Check box in ChemCAD for Windows • Select Unit Operations • Print All Unit Operations: Y Note: Check box in ChemCAD for Windows. • Stream Properties 3 Select or deselect the following stream properties as indicated below: Property Select De-Select OVERALL PROPERTIES Mass flow rate X Mole flow rate Temperature X X Pressure X Mole Vap frac X Enthalpy X Molecular wt. X Total act.dens X VAPOR PROPERTIES Mass flow rate X Mole flow rate X Molecular wt. X Vap. Act. Dens X Vap. Viscosity X Vap. Cp X Vap. Thrm. Cond X Liq. Surf. Tens. X LIQUID PROPERTIES Mole flow rate X Molecular wt. X Liq. act. Dens X Liq. Viscosity X Liq. Cp X 4 Loading and Mapping Simulation Data 136 Property Select Liq. Thrm. Cond. X De-Select SOLID PROPERTIES* Mass flow rate X Molecular wt. X Density X PSD X DISTILLATION OPTIONS Tray profile X Tray properties X Tray sizing X Packed column sizing X TRAY COMPOSITIONS Mass flow rate X * Solid properties are located on Page 2 of Stream Properties in ChemCAD for Windows. The component mass flow rates for individual streams must be included in the output report. 4 Navigate to the Stream Flowrate/Composition menu under the Reports/Output menu. 5 Pick Mass Flowrate. If you want Aspen Process Economic Analyzer to use tray sizing information from the simulator, then you must include the appropriate sizing information. 6 To do this, go to Distillation Summaries under the Reports/Output menu; then select the appropriate sizing section (packed or trayed). 7 After the completion of all these specifications, generate the output report by selecting Calculate and Give Results. This should generate an output report. You can rename it if you wish. This is the file to be used as input for Aspen Process Economic Analyzer. HYSIM Report Generation 1 Copy the following .spc files from the \Program\Load\Hysim directory to your HYSIM working directory before generating output inside the simulator. • MIXER.SPC • TEE.SPC • HTXRATE.SPC • BALANCE.SPC • CALC.SPC • MASSBAL.SPC • MOLEBAL.SPC For all other operations, use the default .spc files provided by Hyprotech. 4 Loading and Mapping Simulation Data 137 2 For HYSIM version 386|C2.12 or earlier, copy the stream format file STRSUM.FMT located in the /Aspen Process Economic Analyzer/Docs directory of your HYSIM working directory. If you have HYSIM version STD:C2.63 and above, copy the stream format file STRSUM2.FMT located in the /Aspen Process Economic Analyzer/Docs directory to your HYSIM working directory and rename it STRSUM.FMT. You must either delete or rename the existing STRSUM.FMT file to perform this. The output report generated from HYSIM should contain operation output (defined as spec_sheet in HYSIM) and the complete stream summary. Both of these outputs must be saved under the same file name. The information is appended to the file and does not get overwritten. To generate the operation output and stream summary (Required): 1 Load the desired project inside HYSIM (*.sim). o operation output o stream summary 2 On the main menu, click Print. 3 On the print option, click File; then press Enter. 4 Select the same file (file_name) as above; then press Enter. 5 Click the Print option; then press Enter. 6 Select the Stream option; then press Enter. 7 Inside the Stream option, select Summary; then press Enter. 8 The list of streams present in the current project is displayed. Click the <> option for all the streams to be written in file_name. The procedure creates the required report (file_name), which can be loaded into Aspen Process Economic Analyzer and used for project evaluation. If sizing operations are performed inside the simulator and you want the information to be carried over to Aspen Process Economic Analyzer, the following steps must be performed in addition to the above procedure: 1 Load the desired project inside HYSIM (*.sim). sizing summary 2 On the main menu, click Size. 3 Inside the size option, choose the unit operation desired; then press Enter. 4 Select the particular equipment (for example, col-101) ; then press Enter. 5 Select auto_section or user_section; then press Enter. 6 After the sizing calculations are performed, select Print. 7 Select File; then press Enter. 8 Select the same file name (file_name) ; then press Enter. 9 Click Summary; then press Enter. Important: • The operation names and stream names can not contain the following characters: 4 Loading and Mapping Simulation Data 138 +, -, *, or spaces • The ASCII report has to be created in the default units specified by HYSIM for the ENGLISH and the SI modes of operation. You can run a simulation in any simulator-provided units. However, prior to creating the report file, you must convert the units to the default specifications provided by HYSIM. • During the sizing procedure for the column operation, if user_section is chosen, care should be taken to check that the stage numbers are not repeated in the different sections of the same column operation. The following two examples demonstrate the correct and incorrect specifications. Correct user_section_1 : Incorrect (start stage) 1 user_section_1 : (end stage) 10 user_section_2: (start stage) 11 (end stage) 10 user_section_2 : (end stage) 15 • (start stage) 1 (start stage) 3 (end stage) 15 The user_section name should not contain the following characters: +, -, * • The report format should be such that the width of the report should be less than or equal to 4 streams wide. This can be accomplished from the format option provided in HYSIM. • Stream summary should follow the operation output in the report, that is, the order should be maintained. HYSYS Report Generation Aspen Process Economic Analyzer’s External Simulation Import Tool imports HYSYS simulator data into Icarus database files, which you can then load into Aspen Process Economic Analyzer. To import HYSYS simulation data for loading into Aspen Process Economic Analyzer: 1 On the Tools menu, click External Simulation Import Tool. The Simulator Link dialog box appears. 2 Click the Browse button for the Simulator File field. 4 Loading and Mapping Simulation Data 139 3 Select the process simulator project you created; then click Open. 4 Click the Browse button for the Export File field. The Export File will contain the exported simulation results data from the selected HYSYS project. Do not include any file extensions for this file. The import tool will automatically assign a d01 extension to this file. 5 Select the location and enter the file name you want to be used to contain the exported data. You can also select an existing file. 6 Click Save. 7 On the Tools menu, click Connect. HYSYS will automatically start with the selected project. The following figure shows the file Cheplant.hsc in the HYSYS interface. 4 Loading and Mapping Simulation Data 140 8 Click Export on the Simulator Link dialog box to start the process of exporting the simulation data from the selected HYSYS project into the Export File. Once finished, you will see five files with the name you gave to the Export File. These files contain the exported data. Note: These files should always go together, in case you want to copy them to another location. D:\test\cheplantn.d01 Å Icarus database file D:\test\cheplantn.d02 D:\test\cheplantn.d03 D:\test\cheplantn.d04 9 On the Simulator Link dialog box, click Disconnect. The tool will close HYSYS. If you want to keep HYSYS running and make changes to your simulation, you can use the Export Again button to export the data again into the Export File. 10 Exit the import tool. 11 Start Aspen Process Economic Analyzer and create a new project. 12 Select Hyprotech’s HYSYS as the Simulator Type. 13 When selecting the simulator report file, select the Export File (the file with the extension .d01) created using the import tool 14 To load, map, and size this project, continue as described in this guide. SimSci’s PRO/II with PROVISION Report Generation Two methods can be used for generating reports from PRO/II with PROVISION. • You can change the input keyword file (*.inp) to include the required print options using keywords for those using PRO/II directly -or• You can change the print options from within the PROVISION user interface. For either method, the operation names and stream names should not contain the following characters: • + • * Note: When specifying sidestrippers, each sidestripper must be identified by a unique four-character name. Currently, sidestrippers are not always identified by their full user-given names in PRO/II with PROVISION report files. Sometimes, they are identified by only the first four characters of the user-given names. Therefore, to properly load sidestripper information into Aspen Process Economic Analyzer, sidestripper Unit identifiers (UID’s) must be used, which are only four characters long. 4 Loading and Mapping Simulation Data 141 To prepare the SimSci report in PROVISION: 1 On the Input menu, select Problem Description. Make sure that the Problem Identifier field is not blank; something must be entered. 2 On the Output menu, select Report Format. 3 On the Report Format menu, select Miscellaneous Data. 4 Set the Report Width field to 80 Columns (the PROVISION default value). 5 On the Report Format menu, select Stream Properties. 6 Select Molar Flowrate and Weight Fraction. 7 On the Report Format menu select Unit Operations. 8 For each column unit operation: A On the Unit Operations list, select Column. B Click the Print Options button while unit is highlighted. C Select Molar Basis from the Column Summary list. D From their respective column print options window, select: o Molecular Weights o Actual Densities o Actual Volumetric Flowrates o Transport Properties o Flowing Enthalpies o Standard Liquid Densities E Click OK. F Repeat for each remaining COLUMN unit operation in list. Note: See the note in the KEYWORD section regarding COLUMN sidestripper’s UID’s. 9 Click Close to finish. 10 Use the default options for remaining unit operations. Using Keywords For General Print Options, use the following keywords: Print INPUT = ALL STREAM = ALL RATE = M WIDTH = 80 For COLUMN operations, use the following keyword: Print PROPTABLES = PART or ALL 4 Loading and Mapping Simulation Data 142 Loading Simulation Data The following loading procedure translates the specified process simulator report file into Aspen Process Economic Analyzer. To load process simulator data: 1 In Project Explorer, Project Basis view, right-click Simulator Type in the Process Design folder; then click Edit. The Select Simulator Type dialog box appears. 2 Click one type from the list; then click OK. Aspen Process Economic Analyzer displays a message saying what the new simulator type is. 3 Click OK. 4 In the Process Design folder, right-click Simulator File Name; then click Edit. 4 Loading and Mapping Simulation Data 143 The Open dialog box appears, showing all simulator files in the Report folder. You can browse other drives and folders as well. 5 Select a file; then click Open. Note: The List view now displays the pathname of the selected simulator file when you select Simulator File Name in Project Explorer. 6 Do one of the following: • On the toolbar, click . -or• On the Run menu, click Load Data. A confirmation window appears. 7 Click Yes. Aspen Process Economic Analyzer loads the simulator data. When the loading of the data is finished, the Process view of Project Explorer is populated with simulator areas and simulator blocks. 4 Loading and Mapping Simulation Data 144 Viewing Data Derived from Simulator To access simulator-derived data (read-only): 1 Right-click a block, and on the menu that appears, click Modify. 2 Click Cancel to close. 4 Loading and Mapping Simulation Data 145 Working with Block Flow Diagrams Aspen Process Economic Analyzer automatically generates a Block Flow Diagram (BFD) from a loaded simulator report. Providing a graphical representation of the process, the BFD displays computational blocks and their connections. The blocks in the diagram correspond to tree items displayed in the Project Explorer’s Process view. Color-coding of the blocks in both the Process view and the BFD agree; mapped items are displayed green and unmapped items are displayed yellow. Displaying the Block Flow Diagram To display the Block Flow Diagram: • On the View menu, click Block Flow Diagram. 4 Loading and Mapping Simulation Data 146 The BFD appears in the Main Window. Note: You can move a block by clicking on the center of the block and dragging it to the desired location. This will also move the streams connected to the block. If the simulator data is reloaded, the block and stream locations will be regenerated by Aspen Process Economic Analyzer. In addition to the blocks displayed in the Process view, the BFD displays streams, direction of stream flows, inlets, and outlets. The commands on the View menu change when the BFD is active. The Drag & Find Feature There is a quick and easy way to find a block on the BFD. Drag the block from the Project Explorer’s Process view and drop it anywhere in the BFD. The part of the BFD displayed changes so that the block you want to find appears in the upper-left corner of the Main Window. 4 Loading and Mapping Simulation Data 147 Drag a block from Project Explorer (Process view) to the BFD Aspen Process Economic Analyzer finds the block on the diagram Accessing Commands in the Block Flow Diagram Right-clicking on blocks in the BFD accesses the same commands available when you right-click a block in Project Explorer’s Process view. Block commands Clicking View accesses simulator-derived data (read-only), as shown on page 145. X43H X The Map command and Delete Mappings command are explained in the next section, Mapping Simulator Items to Icarus Project Components, starting on page 147. Alteration of mapping will alter the blocks' color based on its status. Stream commands You can double-click a stream to access the Develop Stream specifications form. This form is explained on page 116. X435H X Zooming You can use the Zoom In and Zoom Out buttons to increase or decrease the magnification by degrees: You can also select an exact magnification by using the Zoom dialog box. 4 Loading and Mapping Simulation Data 148 To use the Zoom dialog box: 1 On the View menu, click Zoom. The Zoom dialog box appears. 2 Click the desired magnification, or click Custom and type a percentage between 10 and 1,000. 3 Click OK to change magnification and close the dialog box. -orClick Cancel to close the dialog box without changing magnification. The Zoom dialog box also has two options that affect printing: Fit into one page Mark this box to have Aspen Process Economic Analyzer re-size the BFD to fit onto one page when printed. This automatically selects the next option, What-You-See-Is-What-You-Get, since the screen image will reflect the size required to fit on one printed page. What-You-See-Is-What-You-Get (WYSIWYG) When WYSIWYG is cleared, zooming in or out will only affect the magnification factor on the screen, while the printer always prints at 100%. However, if WYSIWYG is selected, the magnification factor on the printer will be changed so that the printed image will have the same size as the image appearing on the screen. 4 Loading and Mapping Simulation Data 149 BlockFlow Diagram View Menu The View menu contains some options that are only displayed when the Block Flow Diagram is active Use this to Toolbar View or hide the toolbar. See page 36 for descriptions of toolbar buttons. Status Bar View or hide the status bar. See page 26 for description of the status bar. Project Explorer View or hide Project Explorer. See page 26 for description of Project Explorer. X436H X X437H X438H X X Palette View or hide the Palette. See page 32 for description of the Palette Properties Window View or hide the Properties Window. See page 32 for a description of the Properties Window. X439H X40H Workbook Mode X Turn Workbook Mode on and off. See page 28 for an explanation of Workbook Mode. X41H Capital Costs View 4 Loading and Mapping Simulation Data X X Launch Aspen Icarus Reporter for interactive reports (on-screen, HTML, or Excel) or Icarus Editor for evaluation 150 reports (.ccp). The Project Evaluation needs to have already been run. See page 405 and page 430 for details. X42H Investment Analysis View X X43H X Display Investment Analysis spreadsheets. See Reviewing Investment Analysis on page 439 for instructions. X4H X Block Flow Diagram Display Block Flow Diagram of the loaded simulator data. Process Flow Diagram Display Process Flow Diagram. This command is not active until you have mapped the simulator items. Streams List Display a read-only list of all simulatorderived stream properties in a spreadsheet. You can customize some of the features of the spreadsheet (which stream properties to display, whether to display names of the properties, and the display style of the property values) by editing the stream list template file: ...\Economic Evaluation V7.0\Data\ICS\strlist.fil Grid Visible View or hide grid lines. Snap to Grid Move blocks in increments corresponding to the grid lines when dragging to new location. Show Page Bounds View or hide page separation lines. When displayed, you can see where page breaks will be when printing. Ports Visible View or hide ports in the Process Flow Diagram. Does not apply to Block Flow Diagram. Zoom Access Zoom dialog box. See page 148. X45H X Mapping Simulator Items to Icarus Project Components Mapping is the process of converting each simulator block (that is, model or unit operation) into one or more Icarus project components. To map simulator items: 1 If you want to map all items, access the Map dialog box by doing one of the following: • Click on the toolbar. -or• On the Run menu, click Map Items. 4 Loading and Mapping Simulation Data 151 2 If you want to map a single block or all blocks in an area, do one of the following: • In Process view, right-click a block or area; then click Map on the menu that appears. -or• In the Block Flow Diagram, right-click a block then click Map on the menu that appears. The Map dialog box appears. Note: If you clicked the Map button on the toolbar or clicked Map Items on the Run menu, only the Map All Items check box is available in the Source section. If you clicked Map on a pop-up menu, both Map Selected Item(s) – the default choice – and Map All Items are available. Select the desired mapping options. Option Description Source 4 Loading and Mapping Simulation Data 152 Option Description Map Selected Item(s) Map the selected simulator block or the simulator blocks in the selected simulator area. This option is available only if you selected Map from a pop-up menu. Map All Items Map all simulator items in the project. Basis Last Mapping Map a block according to the last time it was mapped. This option retains only the type of Icarus project component(s) to which the block was last mapped. Default Use the Component Map Specs file for the basis. Default and Simulator Data Use the Component Map Specs file for the basis, but override the mapping using specific data in the simulator. For example, if you select this option and a reboiler type is specified in the simulator report, an equivalent reboiler type will be used in the mapping. Further, if the Preferences | Process | Use Automatic Mapping Selection when Available was selected, then additional engineering rules of thumb will be used for a selected category of equipments (for example, pumps, compressors, and heat exchangers) to come up the mapping recommendations. (Note: Currently this mode is active only when blocks are mapped one at a time.) Users are encouraged to review these recommendations and either accept them or select a different equipment type based on their knowledge of their processes and practices. Options Size Icarus Project Component(s) Size the mapped Icarus project component(s). If you are mapping a single item to a single component that can be sized using the interactive Sizing Expert, the Interactive Sizing form will appear after mapping. Otherwise, Aspen Process Economic Analyzer uses its automatic sizing. Although the Sizing Expert is unavailable when sizing multiple components, you can still use it later (assuming the component is one of those that can be sized interactively). Just right-click on the mapped component and click Re-Size on the pop-up menu. Note: See Chapter 6 for instructions on using the Sizing Expert. 3 Click OK. 4 Loading and Mapping Simulation Data 153 The Project Component Map Preview dialog box appears. Note: All simulator items are displayed because Map all Items was selected at the previous dialog box. Those components being mapped have asterisks next to them. If you selected Map Selected Item(s) on the Map dialog box, the Simulator Items list displays just the selected simulator block(s). If you selected Map all Items, the Simulator Items list displays all simulator blocks. The Current Map List displays any components that are already mapped to the simulator block highlighted on the Simulation List. The Configuration option box is active only for blocks representing column models. (In the sample project, Block B7 represents a column model.) You must use the arrow scroll buttons to see all ten possible configurations. Selecting a configuration type automatically fills in the Current Map List with the components required for that configuration type. See Tower Configurations for more information. 4 Click New Mapping to map a block highlighted on the Simulator Items list to an Icarus project component. If the simulator block represents a column model that does not yet have all its required mappings, the Select a Suffix dialog box appears, listing the types of components (indicated by suffixes that appear at the end of Item Descriptions on the List view) that still need to be mapped to the block. 4 Loading and Mapping Simulation Data 154 Note: See Tower Configurations for more information. Suffix To indicate bottoms split bottoms splitter bot exchanger bottoms exchanger bottoms pump bottoms pump Cond condenser for the tower cond acc condenser accumulator ovhd exchanger Overhead exchanger Overhead split Overhead splitter ovhd pump Overhead pump precooler first heat exchanger in “split” configuration” Reb reboiler for the tower reflux pump reflux pump Tower main tower Trim second heat exchanger in “split” configuration” Other user-selectable. spray cond Spray condenser spray cond exit pump Pump for recirculating the spray condenser exit sc tot recycle splitter Splitter in Spray Condenser Configuration that generates the total recycle stream sc cooler Heat exchanger in the Spray Condenser Configuration that cools the entire total recycle stream sc tot recycle trim splitter Trim splitter in Spray Condenser Configuration 2 sc trim 5 Heat exchanger in the Spray Condenser Configuration that cools the entire total recycle stream Select a suffix; then click OK. 4 Loading and Mapping Simulation Data 155 The Icarus Project Component Selection dialog box appears. 6 Select a component. The Project Component Map Preview dialog box now displays the component category's item symbol (for example, AG) and the component type (for example, DIRECT) in the Current Map List. More component details are displayed in the Icarus Project Component Description section. 4 Loading and Mapping Simulation Data 156 By default, the Component Name field contains the block name. You may want to modify it to be more descriptive and to distinguish the component from others to which the block has also been mapped. This can be as simple as adding a descriptor at the end. Each component mapped from the block must have a unique name; if another component already has the default component name, Aspen Process Economic Analyzer prompts you to enter a unique name after you select another component. 7 Click OK to complete the mapping. If you selected to size the mapped component(s), Aspen Process Economic Analyzer also performs automatic sizing or, in cases in which a single item is being mapped to a single component for which interactive sizing is available, the Interactive Sizing form appears. See Chapter 6, Sizing Project Components, page 213, for information on this feature. 46H With the block now mapped, the List view displays the components mapped from the simulator block. Component Status You may notice a "?" in the Status column of a project component mapped from the simulator block. This indicates that there are still specifications that need to be entered for the component. To enter the specifications: 1 Right-click the component. 2 On the menu that appears, click Modify Item. 4 Loading and Mapping Simulation Data 157 Entering specifications in the required fields will change the status to OK. Required fields are indicated by color-coding explained on page 186, under Entering Component Specifications. X47H X If you do not enter the specifications and the "?" remains in the Status column, the item will not be included in the project evaluation and will have "0" cost associated with it. It will not cause SCAN messages. Deleting Mappings To delete mappings: • Right-click in the simulator area or simulator block in Process view; then, on the menu that appears, click Delete. Tower Configurations Because a column can be mapped to multiple pieces of equipment, Aspen Process Economic Analyzer requires that you select a tower configuration on the Project Component Map Preview dialog box. You can select from among ten possible configurations: • Standard – Single • Standard – Total • Standard – Total w/Circ. • Standard – Split • Standard – Split Total • Standard – Split Total w/Circ. 4 Loading and Mapping Simulation Data 158 • Full – Single • Full – Single w.Circ. • Full – Split • Full – Split w/Circ. This term means Single Tower has one condenser. Split Tower has multiple condensers. Total the reflux pump handles the total outlet liquid flow from the accumulator. In such configurations, the splitting into a reflux and overhead liquid product occurs after the reflux pump. Circ. there is a pump between the bottoms splitter and the reboiler giving a forced circulation configuration around the reboiler. Note: Full configurations include the following equipment not found in Standard configurations: • overhead pump • overhead product heat exchanger • bottoms product pump • bottoms product heat exchanger Based on the tower configuration selected, Aspen Process Economic Analyzer automatically creates a model for each tower block and then maps the model to an Icarus project component. In addition, you can specify how the condenser requirements should be split between the Precooler and the Trim cooler on the Design Criteria specifications form. If subcooling is present, the precooler will completely condense the overhead vapor and the trim cooler will perform the subcooling; the split specification on the Design Criteria specifications form will be ignored when subcooling is present. The following figures display the ten possible configurations. The default item description suffixes (see page 155) are used to identify the configuration parts, each of which is mapped to an Icarus project component. X48H 4 Loading and Mapping Simulation Data X 159 Figure 1: Standard – Single 4 Loading and Mapping Simulation Data 160 Figure 2 : Standard Total 4 Loading and Mapping Simulation Data 161 Figure 3: Standard Total w/Circ 4 Loading and Mapping Simulation Data 162 Figure 4: Standard Split 4 Loading and Mapping Simulation Data 163 Figure 5: Standard Split Total Figure 6: Standard Split Total w/Circ. 4 Loading and Mapping Simulation Data 164 Figure 7: Full – Single Figure 8: Full – Single w/Circ. 4 Loading and Mapping Simulation Data 165 Figure 9: Full – Split Figure 10: Full – Split w/Circ. 4 Loading and Mapping Simulation Data 166 Figure 11: Spray Condenser Configuration 1 w/Circ. Note: Flow rate of the Spray Cond Total Recycle (SCTR) stream is calculated using Ratio of Recycle to (Ovhdliqprod + Reflux) Flowrates = mSCTR / (mOVH LIQ PROD+ mREFLUX). Ratio of Recycle to (Ovhdliqprod + Reflux) Flowrates is an input specified in the Design Criteria. mSCTR = mass flow rate of the SCTR stream. mOVH LIQ PROD = mass flow rate of the Overhead Liquid Product stream. mREFLUX = mass flow rate of the Reflux stream. 4 Loading and Mapping Simulation Data 167 Figure 12: Spray Condenser Configuration 2 w/Circ. The duty for the SC COOLER and SC TRIM exchangers are calculated using Ratio of SC Trim Duty to Overall Duty = QSCTRIM / QCONDENSER B B B QCONDENSER = QSCTRIM + QSCCOOLER B B B B B B where: Ratio of SC Trim Duty to Overall Duty is an input specified in the Design Criteria QSCTRIM B B QSCCOOLER B B QCONDENSER B B = Spray Condenser Cooler Duty = Spray Condenser Trim Duty = Total Overhead Condenser Duty, obtained from Simulator Data Then the temperatures of the streams exiting the Spray Condenser Cooler and Spray Condenser Trim exchangers are calculated using: a Q = mCpDeltaT calculation. Flow rate of the streams exiting the SC Tot Recycle Trim Splitter are determined using: SC Trim Splitter Flow Split Ratio = mSCRTSEx1 / mSCCEx B 4 Loading and Mapping Simulation Data B B B 168 mSCCEx = (mSCRTSEx1 + mSCRTSEx2) B B B B B B SC Trim Splitter Flow Split Ratio is an input specified in the Design Criteria mSCCE B B mSCRTSEx1 B B = mass flow rate of the SC Cooler Exit Stream = mass flow rate of the SC Rcy Trim Splitter Ex1 Stream (this is the one that subsequently goes through the SC TRIM exchanger) mSCRTSEx2 B B = mass flow rate of the SC Rcy Trim Splitter Ex2 Stream Sizing Selection This section outlines the workflow of the sizing selection feature available in Aspen Icarus Process Evaluator. Sizing selection is a mechanism that lets you pre-define and/or define sizing rules for project components. Specifically, you can set rules on equipment models or specific project components to be sized with one or more custom models. Project Sizing Selection Typically, you load data from a simulation and then choose to map the simulator unit operations. In the mapping screen that appears, there is a check box to Review Sizing Selection. If selected (the default is based on the Tools | Options | Preferences | Process | Sizing selection on the item-size menu), the sizing selection appears. You select any custom model for sizing the project components listed. • If an item is selected, the sizing preview screen appears during a size or re-size performed on one or more project component(s). • If an item is not selected, the mapping preview screen does not appear for editing during these steps, but the sizing selection specifications is applied to the selected project component(s). 4 Loading and Mapping Simulation Data 169 Figure 13: Mapping with option to review sizing selection If selected, you will see the Sizing Selection preview after the mapping preview screen for a chance to edit how the project components are sized (see Figure 14). Figure 14: Sizing Selection preview for specified project components You can specify the sizing routines (System Sizing and custom models) for each project component (created by mapping from a simulator or manual creation) that will be applied during the size-all step. If a custom model is specified in the current sizing list for a project component, the project component will be sized in the order shown in the Current Sizing List (see Figure 14). Any custom models listed will be sized using the custom model tool automatically without any user-interaction 4 Loading and Mapping Simulation Data 170 required. After sizing is complete, the system returns to a ready-state for you to perform additional project tasks. For Global Sizing Selection information, see page 219. X49H X Specifying Additional Components Icarus project components can be added to areas mapped from a simulator report. However, these project components must initially be added in a useradded area. You can later rearrange the components in Project Explorer’s Project view, drag components from a user-added area to an area mapped from the simulator report. Follow the instructions for adding a project component on page 182. X450H X If the component you add is process equipment, Aspen Process Economic Analyzer adds an icon representing the new equipment item in the upper lefthand corner of the Process Flow Diagram (PFD). The next section, Working with Process Flow Diagrams, includes instructions (see Editing Connectivity on page 175) for connecting an added component to a stream in PFD view. X451H72 Working with Process Flow Diagrams Process Flow Diagrams (PFD) provide graphical representations of Icarus process equipment mapped from simulator blocks and the interconnecting streams. You can edit the layout and connectivity of the mapped items from PFD view. You can also add streams. Aspen Process Economic Analyzer provides intelligent port selection, so that when drawing a stream you see the candidate ports highlighted in green as the mouse is moved over them. To access PFD view: 1 On the View menu, click Process Flow Diagram. 4 Loading and Mapping Simulation Data 171 2 Use the Drag-and-Find feature to locate any equipment item on the PFD. 3 Drag an equipment item from Project Explorer (Project view) and drop it on the PFD. The icon in the PFD that corresponds to the selected equipment will be positioned in the upper left-hand corner (regardless of magnification). Editing the Layout To change the position of an item: • Use your mouse to drag the item to its new position. Aspen Process Economic Analyzer reroutes any streams connected to the item. To change the route of a stream: • Click the stream; then drag the stream to straighten it or to create an elbow-bend. Note: If you eventually select Reroute All Streams on the Run menu, Aspen Process Economic Analyzer chooses the most logical routes for all streams. Process Flow Diagram View Menu Note: The View menu contains some options that are displayed only when the Block Flow Diagram is active. 4 Loading and Mapping Simulation Data 172 Use this to Toolbar View or hide the toolbar. See page 36 for descriptions of toolbar buttons. X453H Status Bar X View or hide the status bar. See page 26 for a description of the status bar. X45H Project Explorer X View or hide Project Explorer. See page 26 for a description of Project Explorer. X45H Palette X View or hide the Palette. See page 32 for a description of the Palette. X456H Properties Window X View or hide the Properties window. See page 32 for a description of the Properties window. X457H Workbook Mode Turn Workbook Mode on and off. See page 28 for an explanation of Workbook Mode. X458H Capital Costs View 4 Loading and Mapping Simulation Data X X Launch Aspen Icarus Reporter for 173 interactive reports (on-screen, HTML, or Excel) or Icarus Editor for evaluation reports (.ccp). The Project Evaluation needs to have already been run. See page 405 and page 430 for details. X459H X460H Investment Analysis View X X Display Investment Analysis spreadsheets. See Reviewing Investment Analysis on page 439 for instructions. X461H X Block Flow Diagram Display Block Flow Diagram of the loaded simulator data. Process Flow Diagram Display Process Flow Diagram. This command is not active until you have mapped the simulator items. Streams List Display a read-only list of all simulator-derived stream properties in a spreadsheet. You can customize some of the features of the spreadsheet (which stream properties to display, whether to display names of the properties, and the display style of the property values) by editing the stream list template file: ...\Economic Evaluation V7.0\Data\ICS\strlist.fil Grid Settings Access Grid Properties dialog box, where you can set the grid increments and select to view or hide grid lines. Snap to Grid Move blocks in increments corresponding to the grid lines when dragging to new location. Show Page Bounds View or hide page separation lines. When displayed, you can see where page breaks will be when printing. Ports Visible View or hide ports. Zoom Access Zoom tool. This is the same as in the Block Flow Diagram (see page 148). X462H Add Stream Access the Develop Streams dialog box. See Adding A Stream, page 177, for details. X463H Draw Disconnected Stream X X Access the Disconnected Streams dialog box. See “Drawing a Disconnected Stream,” page 179, for details. X46H Edit Connectivity Activate the Edit Connectivity feature. See “Editing Connectivity,” page 175, for X465H 4 Loading and Mapping Simulation Data X X 174 details. Setting Grid Properties You can select to display grids of any increments. In addition, you can select the color of the grids and whether to be in Snap to Grid mode. To set grid properties: 1 On the View menu, click Grid Settings. The Grid Properties dialog box appears. 2 Set the Across and Down grid increments in the Increments section. Specify in the Units section whether the specified increments are in inches or centimeters. 3 Select the Snap to Grid check box to turn on Snap to Grid mode. When you drag a block in this mode, the block’s bounding outline moves in increments corresponding to the grid. 4 Click Color to select a grid color. 5 Finally, in the Visibility section, click whether to show or hide the grid. 6 Click OK to apply the settings. Editing Connectivity The Edit Connectivity feature lets you make changes to the layout of items in the PFD. Because this involves connecting and disconnecting streams to ports, the Ports Visible option should be on, as it is by default. If the ports are not visible, click the Ports Visible button . Connecting a Stream to Different Inlet Port To connect a stream to a different inlet port: 1 Do one of the following: • On the toolbar, click the Edit Connectivity button 4 Loading and Mapping Simulation Data 175 -or• 2 On the View menu, click Edit Connectivity. Place the cursor over the end of the stream you want to connect to a different inlet port. The cursor becomes an arrow. 3 Click the end of the stream. The cursor now appears as a crosshairs. 4 Move the cursor to another inlet port. When the cursor is in close proximity to a component, the component's available inlet ports display green. 5 Click the new inlet port. Connecting an Added Project Component to a Stream Project components that you add to the project appear in the upper left-hand corner of the PFD and are not connected to any streams. To connect an added project component to a stream: 1 Do one of the following: • On the toolbar, click the Edit Connectivity button -or• 2 On the View menu, click Edit Connectivity. Place the cursor over the added project component that you wish to insert into an existing stream. The cursor becomes a hand. 4 Loading and Mapping Simulation Data 176 3 Click the component. A bounding outline, representing the component, appears around the cursor. 4 Move the cursor over a stream. Click when you have placed the cursor over the desired stream. Aspen Process Economic Analyzer disconnects the Sink end of the stream from the inlet port on the current component, then automatically re-connects it to the inlet port on the inserted component. Aspen Process Economic Analyzer also creates a new stream, which appears white and has properties relative to the initial stream. Aspen Process Economic Analyzer connects the Source end of this new stream to the outlet port of the inserted item and the Sink and to the inlet port of the original. The added item can now be sized manually or using the Size Item option, which either automatically sizes the item or, if interactive sizing is available, accesses the Sizing Expert. The Sizing Expert, explained in Chapter 6, will utilize the newly connected streams. Adding a Stream From PFD view, you can create a new stream and specify its connectivity. The process of developing streams is explained in detail under Developing Streams, page 114. X46H X 4 Loading and Mapping Simulation Data 177 To add a stream: 1 Do one of the following: • On the toolbar, click the Add Stream button . -or• On the View menu, click Add Stream. The Develop Streams dialog box appears. 2 Do one of the following: • To create a stream from scratch, click Create and proceed to Step 3. -or- • 3 To create a stream based on an existing stream, in the Base Stream section, click the existing stream; and then click a Basis: o Absolute If the Basis Mode is Absolute, the data from the base stream is copied to the new stream at the time the new stream is created. If the data of the base stream is altered at any time after this point, the data of the new stream remains unchanged. o Relative If the Basis Mode is Relative, the new stream’s data is dynamically linked to that of the stream on which it’s based. This means that alterations to the data of the base stream immediately affect the new stream. Click Create. 4 Loading and Mapping Simulation Data 178 The Create Stream dialog box appears. 4 Type a name in the Stream Name field; then click OK. The Develop Streams specifications dialog box appears. 5 Make any desired modifications; then click OK. 6 Move the cursor, which appears as a square, to an outlet port. Aspen Process Economic Analyzer provides intelligent port selection, highlighting the candidate ports in green. 7 Click when you have placed the cursor over the desired outlet port. 8 Move the cursor, which now appears as crosshairs, to an inlet port. 9 Click when you have placed the cursor over the desired inlet port. Drawing a Disconnected Stream To draw a disconnected stream: 1 Do one of the following: 4 Loading and Mapping Simulation Data 179 • On the toolbar, click the Draw Disconnected Stream button . -or• On the View menu, click Draw Disconnected Stream. The Disconnected Streams dialog box appears. 2 Click a stream; then click OK. 3 Draw the stream as described in the previous instructions for Adding a Stream. Working with Streams Right-clicking on a stream accesses a pop-up menu with the following commands. Use this to Modify Access the Develop Stream dialog box listing the stream’s specifications, which you can modify. Disconnect Erase the stream from the screen and store it, so that you can select it when using the Draw Disconnected Stream feature (see page 179). Reconnect Source Reconnect the stream to a new outlet port. Reconnect Sink Reconnect the stream to a new inlet port. Delete Delete the stream. X467H 4 Loading and Mapping Simulation Data X 180 5 Defining Project Components When developing an Aspen Process Economic Analyzer project, you can add project components in Project view to user-defined areas (areas not mapped from the simulation report). Once added, you can drag them to different areas. Components are categorized as follows: Note: See ICARUS Reference Guide for information on individual components. Category To define Process Equipment Equipment for gas, liquids and solids handling and off-site/packaged systems. Plant Bulks Material commodities that service a section of the plant or the whole plant. Plant bulks are divided into categories: Piping, Civil, Steel, Instrumentation, Electrical, Insulation and Paint. Site Development Modifications that must be done to the site. Site development items are divided into categories: Demolition, Drainage, Earthwork, Fencing, Landscaping, Roads-Slabs-Paving, Piling and Railroads. Buildings Civil structures directly involved in the process or for off-site use. Quoted Equipment A way to enter special equipment not found in Process Equipment above. Unit Cost Library Items from a Unit Cost Library. See Chapter 7. Equipment Model Library Items from an Equipment Model Library. See Chapter 7. 5 Defining Project Components 181 Adding an Area To add an area: 1 In Project Explorer’s Project view, right-click on the Main Project folder. 2 Click Add Area on the pop-up menu. The Area Information dialog box appears. 3 Define the area, including name, type, and dimensions. The Area Type determines how equipment will be installed in the area. See Chapter 36 of Icarus Reference for information. 4 Click OK. Project Explorer now displays the new area. Adding a Project Component Aspen Process Economic Analyzer provides two methods for adding a project component: 5 Defining Project Components 182 Drag-and-drop Drag a component from the Palette to an area on Project Explorer’s Project view and enter an item description. This adds the component to the area without displaying the Component Specifications form; the specifications are left to be entered at your convenience. Pop-up menu Right-click on an area and click Add Project Component from the pop-up menu, then select a component from the Project Component Selection dialog box and enter an item description. This adds the component and also displays the Component Specifications form, where you can complete the component definition right away. Method 1: Dragging a Component from the Palette To add a component using the drag-and-drop method: 1 With the Palette (Components view) and Project Explorer (Project view) displayed, drag a component from the components list to an area on the Project Explorer. Note: The Recent Items folder in the Components view stores the last 10 project component selections. 2 To drag, click the component and hold down the mouse button. 3 Move the cursor until over the area where you want to place the component. 4 Release the mouse button. 5 Defining Project Components 183 The New Component Information dialog box appears. 5 Enter an item description (required) and User Tag Number (optional), then click OK. The component is added. Project Explorer displays a block for the component under the selected area. The List view displays general information. You may notice a question mark (?) in the Status column on the List view. This indicates that there are still specifications that need to be entered for the component. To enter the specifications, follow the instructions under Entering Component Specifications on page 186. X468H X Method 2: Using the Pop-Up Menu To add a component using the pop-up menu: 1 In Project Explorer, Project view, right-click on a non-simulator area and click Add Project Component on the pop-up menu. 5 Defining Project Components 184 The Project Component Selection dialog box appears. 2 Enter the Project Component Name. 3 Highlight the category to which the desired equipment belongs (process equipment, plant bulks, site development, buildings, quoted equipment) and click OK. Aspen Process Economic Analyzer displays a list of sub-categories. 4 Continue to narrow down the selection to a specific component. Clck OK. 5 The component is added to the area. The Component Specifications form is automatically displayed. You can either complete the definition of the equipment item now or later. 5 Defining Project Components 185 Entering Component Specifications After adding a component, you still need to enter at least some component specifications to complete the component’s definition. Many component specifications have default values used when no value is entered, but most component specifications require further input. If a component added still has any specifications requiring input, a question mark (?) appears in the status column of the List view for that component. You do not have to enter specifications immediately upon adding a component; you may wish to wait until more information about a project becomes available. As more information about a project becomes available, you may also wish to modify previously entered component specifications. The following instructions apply as well to modifying previously entered specifications. To enter or modify component specifications: If the Component Specifications form is not already displayed in the Main Window, display the form by right-clicking on the component and clicking Modify Item on the pop-up menu. You can right-click on the component in either Project Explorer (Project view) or List view (Area level) Double-clicking on the component will also display the Specifications form. Color coding • Red Border: An entry must be made in the field. All specifications forms have at least one required entry field. • Green Borders and Thick Gray Borders: An entry must be made in either the field with the thick gray border or in the two fields with the green borders. The field with the thick gray borders and the fields with the green 5 Defining Project Components 186 borders are mutually exclusive. In the form pictured to the right, either the pump size must be selected or the fluid head and liquid flow rate must be entered. The Properties Window notes this in the Description. Enter the specifications. Note: While on either the component or installation bulks specifications form, you can quickly determine the net effect of all your changes by clicking the Evaluate button and reviewing the resulting report. See page 462 for more information X469H701 X Fields with red borders are required. If there’s a combination of two fields with green borders and one with a thick gray border, an entry must be made either in the two fields with the green borders or in the field with the thick gray border. To define installation bulks for the component: 1 Click the Options drop-down and select the type of bulks to define. See “Defining Installation Bulks” on page 188 for a complete description of installation bulks. X472H X After defining the component and installation bulks, save the specifications form by clicking OK. 5 Defining Project Components 187 Defining Installation Bulks Installation bulks are items directly associated with the component being defined and are used to complete the installation of the item, for example, a foundation for a vessel. The difference between an installation bulk and a plant bulk is that an installation bulk is associated with a component, whereas a plant bulk services the whole plant or mill. Installation bulks may be defined when entering or modifying equipment or plant bulk specifications. Most components are automatically outfitted with installation bulks, so this feature is typically used to adjust, modify, or delete selected bulks. However, because quoted equipment is not automatically outfitted with installation bulks, this feature also serves as the method for defining all installation bulks required for quoted equipment. To access installation bulk specifications: 1 Display the Component Specifications form. 2 Click the down-arrow on the Options button 3 Click the type of installation bulks you want to view or define. . Aspen Process Economic Analyzer displays the specifications form for the selected installation bulk items. See the subsections that follow for descriptions of the different types of installation bulks. 4 When you are done defining the installation bulk, save your changes in either of two ways, depending on what you intend to do next: o 5 Defining Project Components If you want to continue modifying this component’s installation bulks or component specifications, click Apply to save the changes. You can now select either Project Component or another type of installation bulks from the Options menu. 188 o If you are done making changes to the installation bulks and to the component specifications, click OK to save the changes and close the specifications. Note: You can select in Preferences to have Aspen Process Economic Analyzer return you to the main Component Specifications form after you click OK (see page 48). X473H X Mat’l/Man-hours Adjustments Using Mat’l/Man-hours Adjustments, you can specify percent adjustments of system-calculated values as follows: Category Percent adjustment for Equipment Material cost (COA 100-299) Setting Man-hours (COA 100-299) Piping Material costs and/or man-hours (COA 300-399) Civil Material costs and/or man-hours (COA 400-499) Steel Material costs and/or man-hours (COA 500-599) Instrumentation Material costs and/or man-hours (COA 600-699) Electrical Material costs and/or man-hours (COA 700-799) Insulation Material costs and/or man-hours (COA 800-899) Paint Material costs and/or man-hours. (COA 900-999) These adjustments compound material and man-hour indexing applied to the same COA’s. User-entered material costs and man-hours (entered using either Quoted Equipment or Mat’l/Man-hours % Additions) are not affected by these adjustments. A special options section at the bottom of this form allows you to specify non-default installations for the item, including demolition (i.e., dismantlement) of the component and its installation bulks. For example, to demolish a component item: 1 Click Mat’l/Man-hours Adjustments on the Options menu of the Component Specifications form. 2 Scroll down to the Special Options section and, on the Installation Options list, click DEML. 5 Defining Project Components 189 Note: Clicking the demolition (DEML) option causes the following changes to the component: • Material costs are set to zero. • Man-hours and labor costs are charged to demolition COAs (for example, 109, 309, 409, and so on) • Piping and civil man-hours are down-adjusted: 3 o Shop fab man-hours are removed from piping man-hours. o Civil formwork/bracing man-hours are removed. Go back through the Mat’l/Man-hour Adjustments form and make the proper adjustments to account for the relative difficulty of demolition versus new build. For example, if you know unsetting the component is 15% easier than initially setting it, then enter 85% in the Setting labor adjustment field. 4 Save your changes in either of two ways, depending on what you intend to do next: o If you want to continue modifying this component’s installation bulk or component specifications, click Apply to save the changes to the Mat’l Man-hour Adjustments. You can now select either Project Component or another installation bulk from the Options menu. o If you are done making changes to the installation bulks and to the component specifications, click OK to save the changes and close the specifications window. 5 Defining Project Components 190 Note: You can select in Preferences to have Aspen Process Economic Analyzer return you to the main Component Specifications form after you click OK (see page 48). X47H X Mat’l/Man-hours Additions Using Mat’l/Man-hours Additions, you can add lump sum material costs and/or man-hours to a specified COA. All additions are reported “as is.” Additions are neither indexed nor adjusted by Mat’l/Man-hours Adjustments. Up to 20 additions can be defined per component. Pipe – General Specs Use Pipe – General Specs to define the rules for developing all installation piping on the selected component. You can use many fields to define general piping specifications, such as: Material • Pressure • Temperature • Installation - above or below grade • Fluid or electric tracing • Flange class and type • Stress relief • Insulation type • Insulation jacket type • Paint treatment Pipe – Item Details Use Pipe – Item Details to specify individual runs of piping and associated fittings, tracing, paint and insulation. The line is developed using the rules defined in Pipe – General Specs unless they are re-defined with Pipe – Item Details. Up to 40 lines may be defined/adjusted for each component. Note: To reduce the time required to retrieve data when multiple items have been added, select in Preferences to not display all items. If Display P&I Installation Items is unmarked on the Preferences General tab view, selecting Pipe – Item Details will display a dialog box from which you can select the item you wish to edit or select to add a new item. See page 47 for instructions on entering Preferences. X475H X The component starts with piping depicted in the Piping and Instrumentation Drawings manual. You can also display the component’s piping and instrumentation drawing by clicking the P&ID button on the Component Specifications form. It displays the piping you are adjusting on the Pipe Details Installation Bulk form. 5 Defining Project Components 191 You can revise the pipe volumetric model for a component line-by-line. Specifications on the Pipe – Item Details Installation Bulk form override the project-, area- and component-level specifications that otherwise determine the design of all lines of pipe. For example, area dimensions determine all lengths of lines generated by volumetric models except those lines for which you enter a specific length. The Piping Volumetric Model field offers the following options: “blank” - Specified pipe only, no volum. model This option should rarely be used. It is a rapid way to discard the complete piping model for this item; however, in addition to discarding all of the automatically generated lines of pipe, this also discards all the associated drains/vents and pipe-associated instrumentation. The system now generates only piping, drains/vents and on-/in-line instrumentation for those lines that you subsequently define. Once you have used this option, the other options below cannot be used because the model is already discarded. If you subsequently re-create a line that the volumetric model would have automatically created, the associated on-/in-line instrumentation is automatically “re-created.” A - Add line to pipe volumetric model This option is used to add a new line of pipe to a component. The number of the new line must be higher than any other automatically created or userdefined line. For example, if a component generates lines 1 to 6, then an added line may have the number 7 to 40. The area dimensions will have no effect on the length of these lines. It is not necessary to add line numbers in 5 Defining Project Components 192 numeric order; however, they will be generated and reported in numeric order. To associate instrumentation with a new line, specify that a sensor or control element location is this line number. Line 40 is reserved for drains/vents. C - Change lines on pipe volumetric model This is a commonly used option. It is used to modify automatically generated lines of pipe; user-specified lines are not changed. The line is generated exactly at it would have been in the absence of your specifications, except for the items which you change. You may use this to change only the metallurgy, diameter or length of a run, or only the valves and fittings (including setting the quantity to 0) or any combination of these. D - Delete line on pipe volumetric model This option deletes a single line of automatically generated pipe and its associated drains/vents and instrumentation. R - Replace line on pipe volumetric model This option replaces the automatically generated line completely with the exact line that you specify. If you do not define something for this line, you do not get it. For example, if you specify a line of fixed length containing no valves or fittings, then you only get the straight-run of pipe. To make more than one specification for Pipe – Item Details: • Click Add. This adds an item specs column to this form. To delete any unwanted or unused column(s): Click any cell in that column (or drag for a range of columns). Click Delete. Note: Incompletely specified columns must be either completed or deleted before saving. Duct Duct installation bulk items specify individual runs of process ductwork and associated fittings and insulation. Up to 5 duct lines may be specified for each component. Use the same methods described for multiple lines of pipe. 5 Defining Project Components 193 Civil Civil installation bulk items specify bulk excavation and up to three different foundation types/sizes. The available foundation types are listed in the Icarus Reference. From the specified foundation types and volumes, Aspen Process Economic Analyzer calculates: • Excavation and backfill • Form work (plywood/backup lumber with reuse) • Rebar • Sand mat (or ring wall foundation types only) • Grout • Anchor bolts/embedments Steel The Steel installation bulk specifies the following: • Ladders • Stairs • Platforms In addition, up to three different steel items may be specified. Instrumentation Instrument installation bulk items specify individual instrumentation loops or parts of loops with associated sensors, transmitters and signal cabling. Up to 50 loops may be defined for each component. Note: To reduce the time required to retrieve data when multiple instrument items have been added, select in Preferences to not display all items. If Display P&I Installation Items is unmarked on the Preferences General tab view, selecting Instrumentation will display a dialog box from which you can select the item you wish to edit or select to add a new item. See page 47 for instructions on accessing and entering Preferences. X476H X The component starts with instrumentation depicted in the Piping and Instrumentation Drawings manual. You can also display the component’s on piping and instrumentation drawing by clicking the P&ID button the Component Specifications form. It displays the instrumentation you are adjusting on the Instrumentation Installation Bulk form. You can revise the instrument volumetric model for a component loop-byloop. Specifications entered on the Instrumentation Installation Bulk form override the project-, area- and component-level specifications that otherwise determine the design of all instrument loops. 5 Defining Project Components 194 The Instrument Volumetric Model field offers the following options: • blank - Specified loop only, no volum. model This option should rarely be used, It is a rapid way to discard the complete instrument model for this item. The system now generates instrumentation for those loops that you subsequently define. To define new loops, you continue to use this “blank” option for each successive loop. Once you have used this option, the other options below cannot be used because the model is already discarded. • A - Add loop to instr. volum. model This option is used to add a new loop to a component. The number of the new loop must be higher than any other automatically created or user-defined loop. It is not necessary to add loop numbers in numeric order; however, they will be generated and reported in numeric order. For example, if a component generates loops 1 to 6, then an added loop may have the number 7 to 50. • D - Delete loop on instr. volum. model This option deletes a single loop, including sensor, transmitter, cable, control center connections and final control element. • R - Replace loop on instr. volum. model This option replaces the automatically-generated loop completely with the exact loop that you specify. If you do not define something for this loop, or you selectively delete a part, you do not get it. For example, if you specify a sensor and transmitter only, then you only get the signal generated and sent to the control center. • “+” - Append to previous loop w/same no. This option is used to append extra sensors or control valves to the immediately preceding, user-defined loop (you must also correctly specify the loop number of the preceding loop). It may not be used to append items to automatically generated loops; to do this, you should first use the replace 5 Defining Project Components 195 option to redefine the loop, then use the “+” option. Whether you are appending a sensor or control element, you should make entries for both the sensor and control valve locations. To define more than one adjustment, use the same methods described earlier for Pipe – Item Details (page 193). X47H X Instrument Loop Adjustment On the Instrumentation Installation Bulk form, there are eight Loop Modification fields, which allow you to remove different elements of the instrument loop from the project. Select “-” from the drop-down menu to remove an element. Two of the elements, sensor and control valve, can also be specified as quoted (“Q”) or vendor-provided (“V”) equipment. When either “Q” or “V” is selected, the system includes installation manhours for the element but not material costs. Deleting the process connection removes all of the instrument piping. The indicating signal and control signal runs are reported together, so removing one would decrease the amount of cable and supports by half. The following diagram shows how the eight adjustable loop elements fit into the loop design: 5 Defining Project Components 196 Notes: (A) Junction boxes can be found under PLANT BULKS, INSTRUMENTATION, JUNC-BOX. (B) Multi-core runs can be found under PLANT BULKS, INSTRUMENTATION, ELECTRONIC SIGNAL WIRE. You can specify it with or without the junction box. (C) Control centers can be found under PLANT BULKS, INSTRUMENTATION, MULTIFUNCTION CONTROLLERS (electronic) or PLANT BULKS, INSTRUMENTATION, INSTRUMENT PANEL – ANALOG (pneumatic). Electrical The Electrical installation bulk specifies local equipment lighting, control wiring and power/cable and motor starters for up to three different types of electrical loads. Insulation The Insulation installation bulk specifies insulation and fireproofing for component and installation bulk steel. For components, the insulation type, jacket type, thickness and area may be specified. For component and steel fireproofing, type, rating and area may be specified. 5 Defining Project Components 197 Paint The Paint installation bulk specifies surface preparation and painting of component and installation bulk steel. Paint for pipe is specified under piping. Entry field specifications include: • Size of area to be painted • Number of prime and final coats • Percent of painted area to be sandblasted • Galvanizing (for steel) Defining Area Specifications You can define mechanical design and cost basis specifications for the newly added area. You can define or modify area specifications in two ways: • using the Project view • using the Spreadsheet view Method 1: Defining area specifications using Project View To define area specifications using Project view: 1 Right-click on the area in Project Explorer’s Project view and then click Modify on the pop-up menu. Aspen Capital Cost Estimator displays the Area Specifications dialog box. 5 Defining Project Components 198 2 Select the specification category you want to define: Select To do this Area Title Info Change the area title. Area Equipment, Piping, Civil, Steel, Instrumentation, Electrical, Insulation and Paint Define standards and procedures applying to this area only. Overrides specifications entered at the project level for this area only. Area Specs Define area’s type, dimensions, and average high/low ambient temperatures. Area Modules Define module type (default is SKID: flat base structural module); beam, column, and bracing options; structure costs; shipping costs; and impact loads. Material Index Info Adjust area’s system-generated material costs by a percentage. Overrides specifications entered at the project level for this area only. Man Hour Index Info Adjust area’s system-generated man-hours by a percentage. Overrides specifications entered at the project level for this area only. 3 Click Modify to access the selected area specifications. The Area Equipment Specs dialog box appears. 4 Enter area specifications and click OK. 5 Defining Project Components 199 Method 2: Defining area specifications using Spreadsheet View To define or modify area specifications using Spreadsheet view: 1 On the main menu bar, click View | Spreadsheet View | Areas. The Areas spreadsheet view appears. 2 On the Areas spreadsheet view, click Options. 3 On the menu that appears, select the specification category you want to define/modify. Select To do this Area Title Info Change the area title. Area Equipment, Piping, Civil, Steel, Instrumentation, Electrical, Insulation and Paint Define standards and procedures applying to this area only. Overrides specifications entered at the project level for this area only. Area Specs Define area’s type, dimensions, and average high/low ambient temperatures. Area Modules Define module type (default is SKID: flat base structural module); beam, column, and bracing options; structure costs; shipping costs; and impact loads. Material Index Info Adjust area’s system-generated material costs by a percentage. Overrides specifications entered at the project level for this area only. Man Hour Index Info Adjust area’s system-generated man-hours by a percentage. Overrides specifications entered at the project level for this area only. 4 On the spreadsheet, make your modifications. 5 When you are satisfied with your modifications, click Apply. 6 Click OK. Your modifications are made in the project. Note: You cannot use this feature if a component specs form is open that would let you edit data that would also be editable in the spreadsheet view. Importing Areas and Components Using a drag-and-drop operation, you can import entire areas or individual components from other project scenarios. Select in Preferences whether to also include installation bulks and/or connected streams (see page 49). By default, installation bulks are included and connected streams are not. X478H X To import an area or component: 5 Defining Project Components 200 1 Have Project Explorer’s Project view open, since you will drag the component or area there. 2 In the Palette’s Projects view, double-click on the project scenario from which you wish to import. This displays the project areas in the scenario. 3 Expand an area folder to display the components in it. Note: You can only display the areas and components of a scenario that has the same units of measure as the current scenario. If units of measure are different, a message will appear in the Status bar notifying you of this when you double-click on the scenario. To import a component: • Drag the component to the desired area in Project Explorer, Project view. Aspen Process Economic Analyzer adds the component to the area. To import an area and its components: • Drag the area to Main Project in Project Explorer. Aspen Process Economic Analyzer adds the area and its components. To import all the components in an area to an existing area in the current project scenario: • Drag the area from the Palette to the desired area in Project Explorer. Aspen Process Economic Analyzer adds the components to the area without creating a new area. Importing an Entire Scenario As well as allowing you to import individual areas or components, Aspen Process Economic Analyzer lets you import an entire scenario using a dragand-drop operation. This imports all the areas and components in the selected scenario. You can select in Preferences whether to also include installation 5 Defining Project Components 201 bulks and/or connected streams (see page 49). By default, installation bulks are included and connected streams are not. X479H X To import an entire scenario: 1 Have Project Explorer’s Project view open, since you will drag the scenario there. 2 Click the scenario in the Palette’s Projects view. 3 Drag the scenario from the Palette to Project Explorer’s Project view. Aspen Process Economic Analyzer displays a confirmation window. 4 Click Yes. The areas and components of the selected scenario are imported. Note: You can only import scenarios that have the same units of measure as the current scenario. If the units of measure are not the same, a dialog box will inform you of this when you try to import. Copying Components The Copy command copies a selected component and all of its associated installation bulks. This is useful if you want to add a component which is similar to an existing item. The item can be copied and modified with less effort than creating a new item. Remember to change the Item Description when copying components to distinguish the copy from the original. To copy and paste a component: 1 Right-click on the component in either Project Explorer or the List view (at area level, so that components are listed), and then click Copy on the pop-up menu. 5 Defining Project Components 202 2 You can also copy multiple components at once: select the desired components on the List view, right-click on one of the components, and click Copy on the pop-up menu. 3 Right-click on the area to which you want to add the component(s) and click Paste on the pop-up menu. The component is added to the area. Note: If the area contains a component with the same name as the one being pasted, Aspen Process Economic Analyzer changes the new component’s name so that “#1#” appears at the beginning. Cut and Paste If you want to delete (cut) a component from one area and add (paste) it in another area, use the same procedure as above, except click Cut instead of Copy on the pop-up menu. Drag and Drop You can also move a component from one area to another by dragging it. Modifying Components You can modify the following components using Spreadsheet View: • Vessels • Towers • Heat Exchangers • Pumps To modify a component using Spreadsheet View: 1 On the main menu bar, click View | Spreadsheet View | <the type of component to modify>. The <the type of component to modify> spreadsheet view appears. 2 On the <the type of component to modify>spreadsheet view, click Options. 3 On the menu that appears, click the option you want to modify. 4 On the spreadsheet, make your modifications. 5 When you are satisfied with your modifications, click Apply. 6 Click OK. Your modifications are made in the project. Note: You cannot use this feature if a component specs form is open that would let you edit data that would also be editable in the spreadsheet view. 5 Defining Project Components 203 Copying Areas Use Area Copy and Paste to create or modify an area specification that is identical to an existing area. To copy and paste an area: 1 Right-click on an existing area. 2 On the menu that appears, click Copy. 3 Right-click on the project node where you want to copy the area. 4 On the menu that appears, click Paste. 5 In the dialog box that appears, type a name for the new area (for example, area1). The new area is added identical (except in name) to the area you copied. Deleting Components The Delete command removes a component and all associated installation bulks from the project. To delete a component: 1 Right-click the component in either Project Explorer or the List view; then click Delete on the pop-up menu. A confirmation dialog box appears. Note: You can select in Preferences not to have this prompt appear (see page 47). X480H X 2 Click Yes to delete the component or click No to retain the component. 3 You can also delete multiple components at one time: select the components on the List view, right-click one of the components; then click Delete on the pop-up menu. Re-numbering Components After deleting components, you may wish to re-number the remaining components so that the numbering contains no gaps and reflects the order in which components were added. For example, if you add components A, B, C, D, and E in that order, the automatically generated Order Numbers would be 1, 2, 3, 4, 5, respectively 5 Defining Project Components 204 (the Order Number appears on the List view). If you then delete components B and C and re-number, components A, D, and E would have Order Numbers 1, 2, 3, respectively. The order in which they were created would still determine the Order Numbers. To re-number components: • On the Run menu, click Re-number and then click Project Components on the sub-menu. Deleting Areas The Delete Area command removes the selected area and all of its components. To delete an area: 1 Right-click on the area in Project Explorer. 2 On the menu that appears, click Delete Area. A confirmation dialog box appears. Note: You can select in Preferences not to have this prompt appear (see page 47). X481H 3 X Click Yes to delete the area. -orClick No to retain the area. Re-Numbering Areas Areas have reference numbers that are internally stored and then used by the Evaluation Engine. They are not visible in the current version of Aspen Process Economic Analyzer. Just as with components, re-numbering is intended to close gaps in the numbering after deletion. To re-number areas: 1 On the Run menu, click Re-number. 2 On the menu that appears, click Project Areas. 5 Defining Project Components 205 Using the Custom Model Tool Aspen Process Economic Analyzer’s Custom Model tool lets you base component specifications on formulas or fixed data stored in Excel. Use the tool to send a component’s specification values, connection stream values, and specified bulk information (pipe-item details, material and man-hour adjustments) to an Aspen-designed Excel workbook, where you can enter new specification values based on your own data or formulas. Then, use the tool to send the new data back to Aspen Process Economic Analyzer. For instance, you could use the Custom Model tool to calculate a pump driver power based on a flow rate and pump head or to calculate project component costs using your own custom method in Excel. The specifications rules remain stored in Excel, so that you can change the specifications in Aspen Process Economic Analyzer and then revert back to the Excel specifications by re-running the tool (if the values are fixed). Once the tool has been used with a project component, Aspen Process Economic Analyzer associates the customized project component with the last Excel spreadsheet used. Running the tool at the project level updates all components for which the tool has already been run. The tool provides template files for mixers and pumps, as well as a general template to use as the starting point for creating files for other components. However, for components other than pumps and mixers, you must first copy the general template file (or use Save As) and enter the slot names for the component specifications you wish to input, as explained on page 210. 482H To use the Custom Model tool on a project component: Note: Before using this tool, you must select the Activate Custom Model option on the Process tab in Preferences. See page 47 for information on accessing Preferences. 483H 1 In Project Explorer, Project view, right-click the pump or mixer component that you wish to customize. 5 Defining Project Components 206 2 On the menu that appears, click Custom Model. The User Custom Model dialog box appears. It displays the name of the project, scenario, and project component selected for the operation. It also displays available Microsoft Excel (.xls) template files. 3 Click the Excel template file that you have created for the selected project component. 4 Click Run. 5 Defining Project Components 207 Excel displays the workbook, with tabs for: • Input • Custom Rules • Output The Input worksheet displays the original Icarus system values from Aspen Process Economic Analyzer. • Item information is provided at the top of the worksheet. The item information is from the Component Specifications form. • Stream information, if available, is shown toward the bottom. • Below the stream information is information on the installation bulks for Material and Man-hour Adjustments and Pipe Item Detail. The Custom Rules worksheet is provided for storing any data that you may wish to use in the output formulas. 5 Defining Project Components 208 Input specs have been placed on the Custom Rules along with sample alterations for the following: • Mixer with three inlet streams and one exit stream • Pump with connection streams, material and man-hour adjustments • Pipe item details The Output worksheet displays the same component specification slots as on the Input worksheet. However, you can customize the values on the Output worksheet. The values are in the same column-row position as on the Input worksheet, so that you can easily reference the Input data when entering formulas. You send the entries on the Output worksheet to Aspen Process Economic Analyzer by clicking Apply or OK on the Custom Model tool. 5 Defining Project Components 209 The following include customized values based on the sample alterations on the Custom Rules worksheet: • Mixer with three inlet streams and one exit stream • Pump with connection streams, material and man-hour adjustments • Pipe item details These customizations have been entered solely for example purposes. 5 Enter new specifications on the Output worksheet. For example, if you want to double the Input flow rate value provided on Row 10, Column C, enter the following formula: =Input!C10*2 6 Go to the Custom Model tool; then click OK to send the output to Aspen Process Economic Analyzer and close the tool. When you display the specifications form of the component, you will see the values from the Output worksheet. Creating a Template To create a template for a component: 1 Open GeneralModelTemplate.xls; then save it as another file. The folder in which you store Custom Model files is specified on the Locations tab in Preferences (APICustomModelDir). The default is: AspenTech\Economic Evaluation V7.0\Program\API Custom Models 2 Starting on Row 6, Column B for item information, enter the slot names for the specifications that you want to have sent from Aspen Process Economic Analyzer when the file is run for a component. Slot names for every equipment and plant bulk item are provided in Icarus Technology Object Definitions (API.pdf). For example, to have the tool send 5 Defining Project Components 210 Shell Design Temperature to Excel when the file is run for Fixed Tube Heat Exchangers, you would need to enter CPDesignTemperatureShell. 3 For connection stream information, enter slot names starting on Row 43, Column B. 4 For material and man-hour adjustments, enter slot names starting on row 70, column B. 5 For the pipe-item details, enter slot names starting on row 101, column B. Running the Custom Model Tool at Project-Level for Batch Update The batch update process for the Custom Model can be done one of two ways. • The first method is for a batch update of custom model operations performed on project components that are already linked to a custom model template. • The second method is for a batch update of all selected components. After using the Custom Model tool for any number of components, you can continue to experiment with different specifications and easily revert back to the custom specifications by running the tool at the project level. Simply right-click Main Project or Project Area in Project Explorer’s Project view; then click Custom Model. If more than one project component has been selected for the custom model (for example, multi-selection, area selection, project selection), a message box will appear asking you to specify the mode of operation. If you click Yes, you will be able to specify a custom model template and all of the selected project components will be processed with the one chosen template. If you click No, only project components with a link to a custom model template will be processed with their associated template. 5 Defining Project Components 211 Note: the output will be based on the values in the Output workbook in Excel. If the Output workbook contains formulas based on input, changes in input since originally running the Custom Model will affect the output when the Custom Model is re-run. This re-runs all custom models stored in the Custom Model tool. 5 Defining Project Components 212 6 Sizing Project Components Overview Note: To see the list of the Equipment and Slots of those Equipment which will be affected by mapping when you do Map Based On Last Session, see Appendix A. The slots listed on the table in Appendix A WILL CHANGE. Sizing for Project Components Mapped from Simulator Items Operating conditions for the project components mapped from simulator models are obtained from the information loaded into Aspen Process Economic Analyzer from the simulator report. Any Design Data in the simulator report is also loaded and used during sizing. The information consists of a unit operation model and the streams connected to it. You can size a mapped project component in either of two ways: • Right-click the component in Project Explorer and click Size Item on the pop-up menu. • Click the Size button on the Component Specifications form: 6 Sizing Project Components 213 Interactive Sizing Expert For the following components, Aspen Process Economic Analyzer provides the Interactive Sizing form that allows you to adjust sizing specifications. The Interactive Sizing form appears when you size the component. Heat Exchangers DHE FIXED-T-S DHE FLOAT-HEAD DHE U-TUBE DRB KETTLE DRB THERMOSIPH DRB U-TUBE Compressors DCP CENTRIF DCP GEN-SERV DGC CENTRIF DGC CENTRIF-IG DGC RECIP-MOTR EGC RECIP-GAS DCP ANSI DCP ANSI-PLAST DCP API 610 DCP API 610-IL DCP CANNED DCP TURBINE DCP PULP STOCK DCP NAG DRIVE Pumps DCP ANSI DCP ANSI-PLAST DCP API 610 DCP API 610-IL DCP CANNED DCP TURBINE DCP PULP STOCK DCP NAG DRIVE Vessels DHT HORIZ-DRUM DVT CYLINDER DVT SPHERE DVT SPHEROID DVT STORAGE If interactive sizing is not available, Aspen Process Economic Analyzer sizes the item automatically using the simulator data. 6 Sizing Project Components 214 Sizing for Project Components Not Mapped from Simulator Items Project components not mapped from simulator items can be sized if they are connected to streams. See “Creating Streams to Connect to Components” on page 216 for instructions on creating inlet and outlet streams. If the component is one of those for which interactive sizing is available (see list on page 214), the Interactive Sizing form is displayed during sizing. See “Using the Interactive Sizing Form” for instructions on connecting a component to streams during sizing. X48H2165 486H If sizing is not available for a component, the Size option as unavailable. Resizing Project Components If the process conditions associated with a component change, then use the Re-Size command on the project component pop-up menu to update all equipment sizing information. The Re-Size command will clear all the previous sizing results and then size the equipment based on the current process conditions (those that you have entered and those available from the currently loaded simulator file). Therefore, if the component being re-sized is one of those for which interactive sizing is available, the Interactive Sizing form that appears is blank. If you would like to keep some of your component specifications (i.e., not have them replaced by those calculated by the Sizing Expert), do not use the Re-size command. Instead, use the Size command or the Size button to access the Interactive Sizing form with current specifications retained, rather than cleared. Then, clear all fields except those you want to retain and click OK to execute sizing. Aspen Process Economic Analyzer will re-calculate only the blank fields. 6 Sizing Project Components 215 Creating Streams to Connect to Equipment Items For most components, the interactive Sizing Expert requires selection of an inlet stream (that is, a stream carrying fluid to the equipment item) and an outlet stream (that is, a stream carrying fluid from the equipment item). The set of instructions below show how to create streams to connect to an item. In the example, inlet and outlet streams are created to carry 49 DEF F water to a heat exchanger and an outlet stream is created to carry 200 DEG F water from the heat exchanger. In the example used in the set of instructions following these, a heat exchanger is sized to heat water from 40 DEG F to 200 DEG F, using the streams created in the first examples. To create an inlet stream and an outlet stream: 1 In Project Explorer’s Project Basis view, right-click Streams; then click Edit. The Develop Streams dialog box appears. 2 On the Develop Streams dialog box, click the Create tab. 6 Sizing Project Components 216 3 In the Streams tree structure, click User. Leave the Basis as Absolute, since you are creating a completely new process stream. 4 Click Create. The Create Stream dialog box appears. T T 5 On the Create Stream dialog box, enter a stream name, such as Process-IN. 6 Click OK. 7 On the Develop Stream specifications form, specify: o a primary fluid component o temperature o pressure o liquid mass flow Example: 8 and click Water. • In the Primary Fluid Component field, click • In the Temperature (DEG F) field, enter 40. • In the Pressure (PSIA) field, enter 90. • In the Liquid Mass Flow (LB/H) field, enter 50,000. Click Apply. Aspen Process Economic Analyzer fills in the rest of the fields in the Liquid Information section. 6 Sizing Project Components 217 9 Click OK to return to the Develop Streams dialog box, where you now need to create an outlet stream. 10 In the tree structure, click User. Notice that the inlet stream that you just created is now displayed under User. 11 Click that stream and, in the Basis group, click Relative. The new outlet stream will be based upon the inlet stream. 12 On the Create Stream dialog box, enter a stream name, such as Process-OUT. 6 Sizing Project Components 218 13 Click OK. The Develop Stream specifications form appears. Specifications that appear gray are the same as those of the base stream. Any modifications made will appear black. 14 Enter an outlet stream temperature that corresponds to temperature to which the heat exchanger will be heating the fluid. In the example above, the temperature has been entered as 200 DEG F and the pressure has been entered as 80 PSIA. The other specifications are the same as the base stream’s. 15 Click OK to apply the changes and return to the Develop Streams dialog box, which you can now close. Using the Interactive Sizing Form With the necessary streams created, you are ready to perform sizing. 6 Sizing Project Components 219 To size an equipment item: 1 Add an equipment item for which interactive sizing is available and display the Component Specifications form. If you are following the example, add a floating head shell and tube exchanger. (See page 182 for instructions on adding components.) X487H X It is not necessary to enter any values on the specifications form before starting the Sizing Expert. However, all applicable sizing parameters that are entered in the component specifications form will be carried over automatically to the sizing expert and used in calculations. 2 Click the Size button. The Interactive Sizing form appears. Note: In order for the Sizing Expert to run, you must select process fluid streams (one at Inlet and one at Outlet conditions) for at least one side (hot or cold side). 6 Sizing Project Components 220 Any other data you provide (for example,, Duty, Overall heat transfer coefficient, LMTD, and so on) helps the Expert do its job better, but is not necessary. 3 Click on the Hot Inlet Stream field and then click to access a drop-down list that includes all utility resources and user-created streams. Note: “fluid” refers to liquid or gas. 4 If you are heating a fluid, as in the example, select a utility resource to use as the heating source. The tables on the following page provide definitions of the utility resources. To heat a fluid from 40 DEG F to 200 DEG F, as in the example, the utility Steam @100PSI-Aspen Process Economic Analyzer UTILITY is appropriate. 6 Sizing Project Components 221 -orIf you are cooling a fluid, select the stream carrying the fluid to be cooled. Utility Resources If you specify a utility resource as a stream, the Sizing Expert will estimate the actual utility rate required for the heat transfer and use this rate to create utility streams as though they were user-specified. The utility stream names are prefixed by “ICU” and are present under the Utility category in the Develop Streams dialog box. These utility streams differ from utility resources in that they have an actual flow rate whereas a resource is a “reservoir” that can provide utility streams at any required flow rate. Default Utility Resources Available for I-P Projects Inlet temperature Exit temperature Operating Pressure (DEG F) (DEG F) (PSIA) Steam @100PSI 327 327 100 Heat source Steam @165PSI 363 363 165 Heat source Steam @400PSI 444 444 400 Heat source Low Temp Heating Oil 600 550 25 Heat source High Temp Heating Oil 725 675 25 Heat source Refrigerant – Freon 12 -21 -21 15.5 Heat sink Refrigerant – Ethylene -150 -150 15.5 Heat sink Refrigerant – Ethane -130 -130 15.5 Heat sink Refrigerant – Propylene -50 -50 15.5 Heat sink Refrigerant – Propane -40 -40 15.5 Heat sink Cooling Water 95 75 50 Heat sink Utility type Default Utility Resources Available for METRIC Projects Inlet temperature Exit temperature Operating Pressure (DEG C) (DEG C) (KPA) Steam @2760KPA 229.2 229.2 2760 Heat source Steam @1135KPA 184 184 1135 Heat source 6 Sizing Project Components Utility type 222 Default Utility Resources Available for METRIC Projects Inlet temperature Exit temperature Operating Pressure (DEG C) (DEG C) (KPA) Steam @690KPA 164 164 690 Heat source Low Temp Heating Oil 315 287 2523 Heat source High Temp Heating Oil 385 357 2523 Heat source Refrigerant – Freon 12 -29.8 -29.8 105 Heat sink Refrigerant – Ethylene -101 -101 105 Heat sink Refrigerant – Ethane -90 -90 105 Heat sink Refrigerant – Propylene -45 -45 105 Heat sink Refrigerant – Propane -40 -40 105 Heat sink Cooling Water 35 24 105 Heat sink 6 Sizing Project Components Utility type 223 5 Click on the Hot Outlet Stream field and then click to access the drop-down list of utility resources and user-created streams. 6 If you are heating a fluid, select again the utility to use as the heating source. -orIf you are cooling a fluid, select the stream carrying the cooled fluid from the exchanger. 7 to access the Click on the Cold Inlet Stream field and then click drop-down list of utility resources and user-created streams. 8 If you are heating a fluid, select the stream carrying the fluid to be heated. 9 A If you are following the example, select the Process-IN stream that you created in the previous set of instructions (see “Creating Streams,” pages 216 through 219). X48H X X489H X B If you are cooling a fluid, select a heat sink utility to use as a cooling medium. to access the Click on the Cold Outlet Stream field and then click drop-down list of utility resources and user-created streams. If you are heating a fluid, select the stream carrying the heated fluid from the exchanger. If you are following the example, select the Process-OUT stream that you created in the previous set of instructions (see “Creating Streams,” pages 216 through 219). X490H X X491H X If you are cooling a fluid, select again the heat sink utility to use as the cooling medium. Click Apply. Aspen Process Economic Analyzer fills in the other fields on the Interactive Sizing form. 6 Sizing Project Components 224 Note: results are not transferred to the Component Specifications form until you click OK and the sizing is successfully completed (i.e., without generating error messages). 10 Click OK. Aspen Process Economic Analyzer provides a message informing you of the overdesign factor. 11 Click OK to accept this message. The values obtained from Interactive Sizing now appear on the Component Specifications form. 6 Sizing Project Components 225 12 Click OK to save. You can now run an item evaluation and see the values generated by the Sizing Expert in the item report. Global Sizing Selection A user can define and/or select a sizing selection library to pre-define the sizing selection for a project scenario. For each type of component, the user can specify custom models that will be applied in the sizing phase. These rules can also be modified on a component by component basis when working on a specific project scenario. For example, if a user wants to have all “DCP CENTRIF” based equipment models within a project scenario sizing with a specific custom model, he/she can edit or create a Sizing Selection library (see figure 1) to be used. These libraries must be edited/created outside of a project. 6 Sizing Project Components 226 Figure 1: Library tab in palette To edit the library: 1 Double-click the library name (for example, my sizing). The Sizing Selection dialog box appears. 2 To view or edit the sizing selection, click on the equipment model. All equipment models default to “System Sizing” (see figure 2). Figure 2: Sizing Selection dialog box 6 Sizing Project Components 227 3 To add or remove a custom model to the sizing selection list, click New Sizing; then click your choice on the list of available custom models (see Figure 3). Figure 3: Add new sizing with custom model The current sizing list for the equipment model is order dependent (see figure 4). Figure 4: Current Sizing List with System sizing and two custom models Once this library has been specified, it must be selected in the project (see figure 5). Figure 5: Selecting the Sizing Selection library for a project scenario 6 Sizing Project Components 228 Sizing Areas The Area sizing feature in Aspen Process Economic Analyzer develops length and width of an area from the equipment in the area. When actual area dimensions are not available, you can get a better estimate of area length and width from the system when these parameters are not specified in the area specs form. The system calculated area length and width is used in the design of all area bulks. You can use the system calculated area parameters as the area specs. To have Aspen Process Economic Analyzer calculate the area: 1 Open the Aspen Process Economic Analyzer project. 2 Modify an area spec by right-clicking the area; then, on the menu that appears, clicking Modify. 3 Click Specification | Area Specs; then, on the menu that appears, click Modify. 4 Clear the values for Area length and Area width. 5 Click OK; then click Close. 6 Evaluate the project. In the report, the system-calculated length and width for each area appear in: • AREA BULK REPORT • AREA DATA SHEET To specify the area yourself: 1 Open the Aspen Process Economic Analyzer project. 2 Modify an area spec by right-clicking the area; then, on the menu that appears, clicking Modify. 3 Click Specification | Area Specs; then, on the menu that appears, click Modify. 4 Enter values for Area length and Area width. 5 Click Area Piping; then enter data for the piping envelope. 6 Click Area Electrical; then enter data for Distance equipment to panel/DB. 7 Click OK; then click Close. 8 Evaluate the project. In the report, the system-calculated length and width for each area appear in: • AREA BULK REPORT • AREA DATA SHEET To Develop Area Utility Piping and Pipe Racks – system calculated area length and width: 1 Open the Aspen Process Economic Analyzer project. 6 Sizing Project Components 229 2 Modify an area spec by right-clicking the area; then, on the menu that appears, clicking Modify. 3 Click Specification | Area Piping; then, on the menu that appears, click Modify. 4 Clear the data in the Utility length parameter (0) and Utility stations (-) fields. 5 Click OK. 6 Click Area Steel; then, on the menu that appears, click Modify. 7 Clear the data in the Pipe rack length (0) field; then click OK. 8 Close the Area Specification menu. 9 Evaluate the project. Some areas generate utility headers, utility stations. and pipe rack bulks. This information appears in: • AREA BULK REPORT Sizing Requirements, Calculations, and Defaults Certain types of components have minimum input requirements for sizing. Those requirements are provided in the following sections, along with explanations of how the sizing is calculated for different component types. Air Coolers Minimum Input Requirements • Inlet Stream • Exit Stream Sizing Procedure The air cooler thermal and detailed mechanical design equations are given below: For thermal design: Q = U*A*MTD MTD = f*LMTD For mechanical design: A = pi*D_tube*N_tubeRows*N_tubesPerRow* Tube_length 6 Sizing Project Components 230 where: Q = Heat Duty U = Heat transfer coefficient A = Bare tube surface area MTD = Mean Temperature difference LMTD = Log mean temperature difference, based on purely countercurrent flow f = Temperature correction factor N_bays = Number of bays N_tube_rows = Number of tube rows N_tubesPerRow = Number of tubes per row (takes into account the presence of a fan shaft) Tube_length = Length of tubes The process fluid properties (temperature, pressure, and specific heat capacity) are assumed to be constant throughout the air cooler and are estimated as the mean of the inlet and outlet stream properties. The required heat duty is calculated from the inlet and outlet process stream conditions if it is not specified. The process fluid stream temperatures, inlet and exit, are used along with the temperatures specified for the air stream (Design Criteria specifications) to calculate the LMTD. The temperature correction factor is then used to calculate the MTD. If the process fluid temperatures and air temperatures are appropriate, meaning that there is no temperature crossover and the temperature approach at the ends is reasonable, then the surface area required for the given heat duty is estimated using the thermal design equation. The air flow rate needed to realize this heat duty is then calculated using the specified ambient and outlet air conditions. An iterative algorithm has been developed to size the air cooler. The sizing routine calculates the heat duty that can be realized using the specified tube bundle geometry (bay width, number of tube rows, and tube length). It assumes defaults for parameters that you have not specified. If the computed heat duty is larger than the heat duty actually required, the iterative procedure terminates. The tube bundle arrangement used represents the specification of the air cooler selected. If the calculated heat duty does not meet the required heat duty then a bigger air cooler is chosen (i.e. parameter values are increased) and the above procedure is repeated. The iterative procedure terminates either when a tube bundle geometry that can meet the heat duty requirements is found, or when even the largest available air cooler does not meet the process requirements. Air-side heat transfer coefficients are calculated using the relations that take into account the tube bundle geometry. The work of Young, Briggs, and Robinson, as summarized in [6] is being used to evaluate the heat transfer and pressure drop of air across the tube bundle. The pressure drop thus calculated is used in estimating the fan power required. The number of fans required is calculated based on the aspect ratio 6 Sizing Project Components 231 (tube length/bay width). For any aspect ratio of up to 1.5, only one fan is selected. Defaults Tube pitch = 2.5 INCHES Tube thickness = 0.125 INCHES Bay width = 4 ft to 20 ft Tube rows = 3 to 6 Maximum Tube length = 3*Bay width Inlet air temperature (from Design Criteria specifications) Outlet air temperature (from Design Criteria specifications) Agitated Tanks Minimum Input Requirements • Inlet stream • Exit stream Sizing Procedure The capacity of the agitated tank is determined by the following equation: C = Q * (T_r / 60.0) where: C = Capacity , CF Q = Liquid volumetric flowrate, CFH T_r = Liquid residence time, MINUTES The diameter of the agitated tank is determined using L/D and geometry: C = (π/4) * D^2 * L where: D = Diameter of vessel, FEET L = Fluid height, FEET Vessel height is obtained by the following: H = L + h_d where: 6 Sizing Project Components 232 H = Vessel height, FEET h_d = Vapor disengagement height, FEET Design parameters are based on the current Design Criteria specifications if available: Length/Diameter Ratio: Default = 3 Vapor disengagement height: Default = 1 FEET Agitator type: Default = = = ANCHOR Driver type: Default Impeller type: Default STD T6FB Operating pressure is obtained from the simulator report. If the report does not have a value, then the pressure of the inlet stream having the maximum value is chosen as the operating pressure. The operating pressure is used to obtain the L/D ratio (if user specification is absent). If P <= 250 PSIA, then L/D = 3 If 250 < P <= 500 PSIA, then L/D = If P > 500 PSIA, then L/D = 5 4 where: P = Pressure, PSI L = Fluid height, FEET D = Diameter of vessel, FEET The project component must have at least one process stream connected to the inlet and exit. Also, since the sizing procedure is based on the liquid holding period, at least one of the streams should have liquid phase. The design pressure and temperature are based on the operating pressure and temperature as modified by your entries on the Design Criteria specifications form. Compressors Minimum Input Requirements • Inlet and Exit stream information • Driver Power (for Reciprocating Compressors) 6 Sizing Project Components 233 Sizing Procedure The capacity requirement for the compressor is calculated from the inlet stream information. The inlet stream flow rate and density are used to estimate the total volumetric flow rate through the compressor. The compression ratio (exit to inlet pressure) is obtained from the operating pressures of the inlet and exit stream. The compressibility factor (inlet and exit) is based on user-specified information, if available, or estimated by the sizing expert based on the Primary Fluid Component. The Icarus Evaluation Engine estimates the driver power if it is neither userspecified nor provided in the simulator report. The engine currently uses a mechanical efficiency of 100% to arrive at the brake horsepower. The brake horsepower, thus calculated, is compared against a table of available standard motor sizes. If the calculated brake horsepower is not found in the table, then the motor with the next higher horsepower is selected. If the driver horsepower is either user-specified or provided in the simulator report, the engine uses this value. However for pricing the compressor, the table of available standard motor sizes is referred. If the specified horsepower is not found in the table, then the price of the motor with the next higher horsepower is used. In the case of simulator inputs, different simulators provide information that may be slightly different. For instance, in the case of AspenPlus, the compressor calculations take into account any mechanical efficiency specified during the simulation run. So the “brake horsepower” reported in the case of AspenPlus already takes into account the mechanical efficiency. However, other simulators, such as SimSci (“Actual Work”); HYSIM and HYSYS (“Energy Required”), and ChemCAD ( “Actual Power”); do not account for mechanical efficiency. Keep this in mind and be aware of what has been accounted for in the simulation side when using simulator information as inputs. Defaults Minimum inlet pressure for air compressors is 14.696 PSIA Crushers Minimum Input Requirement • Inlet and Exit stream information • Final product size. Sizing Procedure The sizing expert estimates the solid flow rate from the inlet stream information. The crushing ratio (feed to product size) is set at 4. Work index is the total energy in KWH/TONS, needed to reduce the feed to a size so that 80% of the product will pass through a 100 micron screen. The 6 Sizing Project Components 234 sizing expert in Aspen Process Economic Analyzer assumes a default value of 13.81 for the material work index. The total driver power required for the crusher is calculated using material work index and the value of the product size. The following equation is used to estimate the driver power: P = 1.46 (T_m) (W_i) ( 1/(d_p ^ 0.5) - 1/(d_r ^0.5)) where: P = Driver power, HP T_m = Crusher capacity, TPM W_i = Material work index d_p = Product size, FEET d_r = Feed size, FEET Defaults • Material Work Index: 13.8 KWh/ton • Size Reduction Ratio: 4 Crystallizers Minimum Information Required Inlet and Exit Stream information Additional Information Final Product size Sizing Procedure The sizing program calculates the crystallizer capacity based on the inlet and exit stream information. Default value of 0.83 MM is used as final product size if the user-specified value is not available from the simulator report. In addition, the following defaults values are used for the design parameters: Growth rate = 0.36 MM/H The residence time in hours for a batch crystallizer is determined by the following relation: Residence time = d_p / (3 * R_g where: 6 Sizing Project Components 235 d_p = Product size, MM R_g = Growth rate, MM/H Based on the minimum and maximum values for the required fields in the component specification form, the number of additional crystallizers are estimated. Dryers Minimum Input Requirement Inlet and Exit stream information Sizing Procedure The sizing program calculates the dryer capacity based on the total evaporation rate for the drying process. For tray and drum dryers, an average depth of 2.25 FEET is used to determine the total dryer requirements. For vacuum and jacketed rotary vacuum dryers, the dryer capacity is determined by obtaining value of the drying time and the average percentage utilization of the dryer capacity. The system defaults are as follows: Drying time = 0.75 HOUR Average percentage utilization = 25 The number of additional items required for the given drying operation is determined from the knowledge-based engine in Aspen Process Economic Analyzer, which analyzes minimum and maximum values for the required fields in the specification form. Dust Collectors Minimum Input Requirement Inlet and Exit stream information Sizing Procedure The sizing program estimates the vapor volume flowing through the dust collector using the exit stream information available from the simulator report. In case of cyclones, the sizing program assumes a default linear velocity of 150 FPS. The height to width ratio is fixed at 2.5. 6 Sizing Project Components 236 Using the above defaults, the volumetric rate through the separator is obtained using Zenz correlation represented by the following equation: Q = 2.5 (D ^ 2) V / 16 where: Q = Vapor volumetric rate, CFS D = Cyclone separator diameter, FEET V = Linear velocity, FPS In case of baghouse dust collectors, the sizing program uses Nylon as the default filter cloth material to determine the air to media ratio which then determines the diameter of the separator. Air to media ratio is the flow rate of air (at 70 DEG F) in CFM. The default ratio results in a pressure drop of 0.5 INCHES of water when passed through 1 SF of clean fabric. The sizing program uses a default air to media ratio of 10 CFM. The minimum and maximum values of the required field(s) shown in the component specification form are used to determine the number of identical equipment items. Filters Minimum Input Requirement • Inlet stream • Exit stream Sizing Procedure The sizing program calculates the total amount of filtration product rate based on the exit stream information. Based on the type of filter selected, the average dimension of the filter equipment is selected and the filter size is then optimized for the given operation such that the dimensions selected for the equipment are within the minimum and maximum values as specified by the knowledge-based engine. In case of batch filtration, a default batch time of 0.25 HOUR is used. In case of plate and frame filters, default value of cake thickness of 0.3 FEET is used. In the case of continuous operation, the cycle time default is 0.08 HOUR. Based on the actual capacity requirement and the maximum and minimum sizes provided by the knowledge-based engine, the number of identical items is determined. 6 Sizing Project Components 237 Heat Exchangers The heat exchanger sizing program estimates the heat transfer area required for the given operating conditions. The model also performs detail estimation of the number of tubes, tube length, and other internal components of the heat exchanger based on either user-defined specifications (from the process simulator report or the Design Criteria specifications form) or system defaults. Minimum Input Requirements Inlet and Exit Process Stream Information Sizing Procedure The process stream(s) are classified into various categories. The Primary Fluid Component class that you specify for the process fluid(s) flowing through the heat exchanger is used to estimate the following design parameters: • Latent heats (vaporization and condensation) • Fouling resistance • Specific heat capacity of the fluid • Liquid film resistance • Overall heat transfer coefficient Duty requirement for the heat exchanger is either directly obtained from the simulator report or estimated based on the inlet and exit process stream information for the process model. In case the fluid undergoes phase change, a boiling point temperature, Tb, is estimated that would lie between the inlet and exit stream temperature. The estimated Tb is then used in the calculation of the sensible and latent heats based on the Primary Fluid Component. The sensible heat of any solids present in the stream is also accounted for in the duty calculation. In estimating the design pressure on shell and tube heat exchangers, the 2/3rd Rule is applied if it has been selected on the Design Criteria specifications form (see page 86). P P X492H X If only the process fluid conditions are specified by the simulator model, the heat exchanger sizing program determines the appropriate utility from the list of utilities that you specify using the Utility Specifications accessed from Project Basis view (see page 98). If multiple utilities are available for heat transfer, then the sizing expert uses the utility fluid with a temperature approach closest to the process fluid. This minimizes the heat transfer losses. However, a minimum of 1 degree Fahrenheit difference in the final temperature of the process fluid and the utility fluid must exist for the utility fluid to be selected for the process. If an appropriate utility fluid is not available for the heat transfer process, the heat exchanger sizing program will terminate without estimating the heat exchanger size requirements. X493H X The mean temperature difference (MTD) is estimated based on the fluid temperature for both the shell and the tube side. It also depends on the flow configuration for shell and tube heat exchangers, which is specified by the number of shell and tube passes. For reasons of compactness of equipment, the paths of both fluids may require several reversals in direction. Mean 6 Sizing Project Components 238 temperature differences in such cases can be obtained by applying a factor (called the F-factor) to the terminal temperature difference. The logarithmic mean temperature difference (based on purely counter current flow) is multiplied by the F-factor to obtain the mean temperature difference. If the temperatures are not properly entered then appropriate warning messages are displayed. In such cases it recommended that you check the inlet and outlet temperatures of the shell and tube side streams and verify that they are realistic. The overall heat transfer coefficient is either directly obtained from the simulator report or evaluated based on the shell and tube fluid properties (film resistance, fouling tendency present for the various processes in the system database). The heat exchanger sizing program determines the position of the fluids in the shell and tube heat exchanger. The position depends on both the process and utility fluid class. If duty is provided by the simulator report, then you can override the value only through interactive sizing. The final heat transfer area is obtained by multiplying the heat transfer area, calculated based on the duty required, with the Heat Exchanger Minimum Overdesign Factor. If you do not specify an overdesign factor then the default value is used from the Design Criteria specifications. If the duty generates a surface area less than minimum required for practical design, the item report will give the appropriate warning message. FLOAT HEAD or U-TUBE heat exchangers have an even number of tube passes. If you enter an odd number for the number of tube passes for any of these heat exchanger types, Aspen Process Economic Analyzer generates warning messages. The shell and tube design pressure and temperature are based on the maximum operating conditions of the fluid flowing through the shell and tube respectively. The Design Criteria specifications form allows you to change them according to individual project requirements. Heat Exchanger Internals The final heat transfer area is determined by the actual number of tubes chosen for the equipment. The least surface area of the combination of numbered tubes and shells is changed for final design. A default tube length of 20 FEET is used for calculating the number of tubes. System default values for tube diameter, tube thickness, tube pitch and baffle distances are used if user specifications are not available. General Information The utility requirement is estimated only when the system determines the utility fluid. If both shell and tube side fluid stream information is specified in the simulator report, then the system assumes that both of the fluid streams are process streams and that no utility fluid is expended. 6 Sizing Project Components 239 Presently, the model defaults are used for determining the material of construction. For shell and tube heat exchangers, if the heat transfer surface area calculated by the sizing program is greater than the largest heat exchanger designed by the design and cost engine, then the heat exchanger is divided into multiple shells with identical configurations. The capital cost estimation is then calculated based on the complete heat exchanger. Note: When mapping a rigorous heat exchanger model (HXRIG) from SimSci, the number of shells in parallel is used to determine the number of shells in Aspen Process Economic Analyzer. For Aspen Process Economic Analyzer, the maximum number of shells in series is 1. Double Pipe Heat Exchanger The sizing program in Aspen Process Economic Analyzer estimates the total surface area required for the given duty. During the capital cost estimation, detailed design for the heat exchanger is developed based on the values for tube length and number of tubes per shell obtained from the simulator report or from the user. Fin Tube Heat Exchanger The sizing program estimates the total surface area required for the given duty. During the capital cost estimation, detailed design for the heat exchanger is developed based on the tube length and number of fins per tube obtained either from the simulator report or from the user. Spiral Plate Heat Exchanger The sizing program estimates the total surface area required for the given duty. During the capital cost estimation, detailed design for the heat exchanger is developed based on the tube length and number of fins per tube obtained either from the simulator report or from the user. Pumps Minimum Input Requirements Inlet and Exit stream information Sizing Procedure The sizing program calculates the total capacity requirements for the selected pump based on the total flow rate of the inlet fluid stream(s) obtained from the simulator. 6 Sizing Project Components 240 Flow Rate/Capacity Pump flow rate is obtained from the simulator information. If the information does not exist, then pump flow rate is calculated based on the stream flow rates. The stream is assumed to be completely liquid phase and no check is made for presence of vapor phase. The pump flow rate obtained from the simulator information is multiplied by the pump overdesign factor, also referred as the capacity over-design factor, present in the Design Criteria specifications file. Pump % Efficiency Pump efficiency is directly obtained from the simulator. If the value is not present in the simulator report, then the default value of 70% is used. Pump Overdesign You can modify the pump overdesign factor either on the Design Criteria specifications form or the Interactive Sizing form. Modifying the overdesign factor using the Design Criteria specifications form (page 86) will applies the new factor to all the pumps in the project. Modifying the overdesign factor for a pump using the Interactive Sizing form (page 219) applies the factor only to that particular pump. This allows you to either specify the factor for all pumps or specify the factor individually for each pump. X49H X495H X X Driver Power If you specify a driver power in the component specification form then this value is used. If the user does not provide the value then it is calculated by the cost engine. The Icarus Evaluation Engine calculates the hydraulic horsepower based on the capacity, viscosity and head, and then uses the pump efficiency to estimate the brake horsepower. The brake horsepower is compared against a set of standard available motor sizes to estimate the pump driver power. If multiple inlet streams are present, the minimum value of pressure is used for determining the operating pressure of the equipment. Defaults (if they are not obtained from the simulators): • Operating pressure: 14.696 PSIA • Operating temperature: 77 DEG F Calculating Pump Head The total head developed by the pump is composed of the difference between the static, pressure, and velocity heads. Additionally, friction at the suction and discharge sides would also contribute to some head loss. The pump head is calculated using the following relation: Head, = h_d – h_s 6 Sizing Project Components 241 FEET where: H = total pump head, FEET h_d = = discharge head, FEET h_s suction head, FEET Assumptions: • No friction losses at the entrance and exit. • No static head on suction and discharge sides. • Velocity heads are not included in estimating the suction and discharge heads. Head in feet is estimated by the following relations: Head, FEET = (Pressure, PSIA) * (2.31)/(Fluid specific gravity) The specific gravity of the fluid is based on inlet streams conditions. The discharge pressure for the pump is based on the maximum value for the exit stream(s). The suction pressure is based on the minimum value for the inlet streams(s). Screens Minimum Input Requirement • Inlet stream information • Screen opening size (or average product size) Sizing Procedure The sizing program determines the capacity of the screen based on the inlet flow rate estimated from the stream information. The screen opening size is used to determine the final product size. The feed material for the vibrating screen is obtained from the Design Criteria specifications. The following choices are available: • Sand and Gravel • Limestone/Crushed Stones • Coal • Cinders • Coke • Wood The material type affects the screen unit capacity which is defined as the amount of solid (in tons per hour) flowing through one square foot of screen 6 Sizing Project Components 242 cloth based on material, having 6 to 8% moisture, screen cloth having 50% or more open area; 85% screen efficiency. Based on the material selected and the screen opening size, the screen unit capacity is chosen. Further, the sizing program assumes that five layers of particles are present on the screen. The surface area required for the vibrating screen is obtained. Based on the maximum and minimum values specified by the knowledge base for the screen capacity, additional items required by the operations are determined. Towers Minimum Input Requirements • Stage temperature, pressure, flowrates • Number of stages • Inlet stream • Exit stream Sizing Procedure The distillation column sizing module can be used to size the following Icarus process equipment: • DDT TRAYED • DDT PACKED • TW TRAYED • TW PACKED • DC HE TW The following simulator models can be used to generate the necessary process information required for successfully executing the application: Simulator Models used AspenPlus ABSBR, DISTWU, DISTL, RADFRAC HYSIM/HYSYS COLUMN Pro/II COLUMN, IO, SURE, CHEMDIST, SHORTCUT Loading Column Model from Simulator In Aspen Process Economic Analyzer, the rigorous column unit operations loaded from the simulator report (i.e., COLUMN UNITS model in PRO/II) are developed in great detail, including all pieces attached to the main column unit. Typically, the simulator model develops stage information for the main tower and duties for an associated condenser and reboiler. These duties are used along with the specified fluid conditions available from the stage information tables to generate all of the input specifications required for the equipment. 6 Sizing Project Components 243 Sidestrippers and pumparounds are separated from the main tower if necessary during the loading process after all the relevant information is collected for the models. Once the report is loaded, these units are treated as separate simulator models which can be mapped and sized independently of the main tower design. Sidestrippers Sidestrippers attached to tower models are separated from the main tower model during the loading process. Sidestrippers load information from the same tables in the report from which the main tower information is discerned. For example, the typical information loaded for sidestrippers in Pro/II are: SIDESTRIPPER ABC COLUMN SUMMARY TRAY TEMP PRESSURE DEG C KPA ————— ————— ———————— 1/ 10 200.3 600.50 2/ 11 202.2 601.53 —————— NET FLOW RATES —————— HEATER LIQUID VAPOR FEED PRODUCT DUTIES KG-MOL/HR M*KJ/HR —————— —————— ————— ——————— ——————— 22. 7.8 20.0L 5.0V 8.5V 20.1L SIDESTRIPPER ABC TYPE STREAM PHASE FROM TRAY ————— —————— —————— ————— FEED ABCDRW LIQUID FEED ABCSTM VAPOR PROD ABCSRVP VAPOR 10 PROD ABCPRD LIQUID 11 TO TRAY ——— 10 11 LIQUID FRAC —————— 1.0000 .0000 FLOW RATES KG-MOL/HR —————————— 23.00 5.55 8.46 20.09 HEAT RATES M*KJ/HR ——————————— 1.3216 .2785 .5325 1.0678 Information is obtained for the sidestrippers in the same manner as for the main tower unit (Refer to information for obtaining process data for main tower unit). Pumparounds The inlet and outlet fluid conditions for pumparounds are obtained from the stage information to which the unit is connected. Additionally, the duty associated with each pumparound is loaded into the unit. This unit is then separated during the loading process and is treated as an independent simulator model which can be mapped and sized on its own. For example, the information required by pumparound units in PRO/II are obtained from the following part of the column report: COLUMN SUMMARY ————— NET FLOW TRAY TEMP DEG F ———— ————— . . . 40R 355.9 RATES ————— PRESSURE LIQUID PSIG ———————— —————— 33.00 5618.9 HEATER VAPOR FEED PRODUCT LB-MOL/HR ————— ————— ——————— 4301.4L DUTIES MM BTU/HR ————————— 94.6551 PUMPAROUNDS TRAY TEMP, FROM TO FROM —— —— —————— 40 40 355.9 6 Sizing Project Components DEG F LIQUID FRACTION ——————————— RATES ——————————— TO FROM TO LB-MOL/HR M LB/HR STD BBL/HR ————— —————— ————— ————————— ———————— —————————— 416.1 1.0000 .4108 7273.09 995.238 3569.48 244 Mapping the Tower Model Typically, column models in simulators do not include the ancillary equipment attached to the main tower. For example, a tower unit may really consist of the following equipment: • Main tower • Overhead condenser • Condenser accumulator • Overhead split • Reflux pump • Overhead pump • Overhead product sub-cooler • Reboiler • Bottoms split • Bottoms product pump • Bottoms product heat exchanger Both overhead and bottoms split are process stream splitters and therefore do not represent any project component. In Aspen Process Economic Analyzer, during mapping and sizing process, they are typically mapped as a quoted cost item with zero cost. In addition, the equipment design could involve splitting the units into more than one actual piece for reasons of economy. For example, in many applications, condensers are split into a precooler (which is typically an air cooler but also can be any other type of heat exchanger) and a trim cooler (typically a shell and tube heat exchanger). Tower models (such as RADFRAC model in AspenPlus, COLUMN UNIT in PRO/II and COLUMN in HYSIM/HYSYS) can be mapped into any of the following ten Aspen Process Economic Analyzer configurations: • • Standard - Single or Standard - Total o Tower o Condenser o Condenser accumulator o Overhead split o Reflux pump o Bottoms split o Reboiler. Full - Single o Tower o Condenser o Condenser accumulator o Overhead split o Reflux pump o Overhead pump 6 Sizing Project Components 245 • • • • o Overhead product heat exchanger o Bottoms split o Reboiler o Bottoms product pump o Bottoms product heat exchanger Standard - Split or Standard – Split Total o Tower o Precooler o Trimcooler o Condenser accumulator o Overhead split o Reflux pump o Bottoms split o Reboiler Full - Split o Tower o Precooler o Trimcoooler o Condenser accumulator o Overhead split o Reflux pump o Overhead pump o Overhead product heat exchanger o Bottoms split o Reboiler o Bottoms product pump o Bottoms product heat exchanger Standard - Total w/Circ. o Tower o Condenser o Condenser accumulator o Overhead split o Reflux pump o Bottoms split o Reboiler o Circulation pump Full - Single w/Circ. o Tower o Condenser o Condenser accumulator o Overhead split o Reflux pump 6 Sizing Project Components 246 • • o Overhead pump o Overhead product heat exchanger o Bottoms split o Reboiler o Bottoms product pump o Bottoms product heat exchanger o Circulation pump Standard – Split Total w/Circ. o Tower o Precooler o Trimcooler o Condenser accumulator o Overhead split o Reflux pump o Bottoms split o Reboiler o Circulation pump Full - Split w/Circ. o Tower o Precooler o Trimcoooler o Condenser accumulator o Overhead split o Reflux pump o Overhead pump o Overhead product heat exchanger o Bottoms split o Reboiler o Bottoms product pump o Bottoms product heat exchanger o Circulation pump Refer to Tower Configurations in Chapter 4 for detailed flow diagrams. These configurations should be regarded as the “maximum” model with all potentialities satisfied The components actually developed depend upon the process conditions. For example, if the main tower model does not have a condenser and a reboiler, then only the tower model is mapped. If the overhead product is cooler than the temperature of the fluid from the condenser outlet, then an overhead exchanger is mapped. A bottoms product exchanger is mapped only when the bottoms product stream has a different temperature from the temperature of the bottom stage of the tower. In the case of split models, where the condenser duty is split into precooler and trimcooler duties, the ratio of the duty split is obtained from the Design 6 Sizing Project Components 247 Criteria specifications form. The overhead vapor stream flowing to the precooler is assumed to be at dew point if the condensation temperature is not provided. Loading Tower Input Information From the tower results in the report, the tables consisting of stage temperatures, stage pressures, stage molar vapor flow rates and stage molar liquid flow rates are loaded in the mapping process. For example, in the case of AspenPlus, the following tables in the RADFRAC block are loaded by Aspen Process Economic Analyzer in the mapping process: Table 1: Stage temperature and Stage Pressures are loaded (Column 1 and 2) ENTHALPY STAGE 1 2 3 4 5 6 7 8 9 10 TEMP. F PRESSURE PSI 149.27 223.45 227.79 230.39 232.06 233.25 234.18 234.98 235.72 236.74 20.000 22.000 22.100 22.200 22.300 22.400 22.500 22.600 22.700 22.800 BTU/LBMOL LIQUID VAPOR -0.12156E+06 -0.11895E+06 -0.11909E+06 -0.11918E+06 -0.11925E+06 -0.11931E+06 -0.11935E+06 -0.11939E+06 -0.11942E+06 -0.11941E+06 HEAT DUTY BTU/HR -42602. -.23509+08 -87138. -92519. -95701. -97662. -98970. -99924. -0.10068E+06 -0.10135E+06 -0.10196E+06 45802+08 Table 2: Stage molar liquid flowrates and Stage molar vapor flowrates are loaded. (Column 1 and 2) STAGE FLOW RATE FEED RATE PRODUCT RATE LBMOL/HR LBMOL/HR LBMOL/HR LIQUID VAPOR LIQUID VAPOR MIXED LIQUID VAPOR 1 2 3 4 5 6 7 8 9 10 1239. 0.2571E+05 0.2586E+05 0.2595E+05 0.2602E+05 0.2606E+05 0.2610E+05 0.2614E+05 0.2617E+05 0.2357E+05 430.0 .57657-01 1669. .24001+05 2140. 2286. 2380. 2444. 2493. 2532. 2568. 2604. 430.0000 .23571+05 Inlet and exit streams (and their stage numbers) are loaded in the mapping step. For example, in the case of a RADFRAC model for AspenPlus, the following portion of the report is loaded in Aspen Process Economic Analyzer: INLETS7 OUTLETS - 8 9 STAGE 2 STAGE 1 STAGE 10 When sizing information is present in the report, the mapping program loads all the relevant information present in the sizing sections. 6 Sizing Project Components 248 For example, in the case of a RADFRAC model for AspenPlus, the following portion of the sizing report is loaded in Aspen Process Economic Analyzer for every section: Case : Tray tower sizing section STARTING STAGE NUMBER ENDING STAGE NUMBER TRAY SPECIFICATIONS — — — — — — — — — TRAY TYPE TRAY SPACING 2 29 METER SIEVE 0.60960 ***** SIZING RESULTS @ STAGE WITH MAXIMUM DIAMETER ***** COLUMN DIAMETER METER 4.00228 Case : Packed tower sizing section STARTING STAGE NUMBER ENDING STAGE NUMBER PACKING — — — — PACKING HETP PACKING 2 9 SPECIFICATIONS — — — — — — — TYPE HEIGHT FT FT BERL-SADDLE 2.00000 16.0000 Determining Tower Process Conditions • Operating Temperature The maximum temperature value for all the stages (given by column 1) is used as the operating temperature for the tower. • Operating Pressure The maximum pressure value for all the stages (given by column 2) is used as the operating pressure for the tower. • Minimum Operating Pressure The minimum pressure value for all the stages (given by column 2) is used as the minimum operating pressure for the tower. • Design Pressure The maximum value from the stage pressure profile is used for calculating the design pressure of the tower (that is, after applying the user-defineddesign value from the design criteria file). When stage pressures are not available, the maximum value of pressure from all the inlet streams is used. • Design Temperature The maximum value from the stage temperature profile is used for calculating the design temperature of the tower (that is, after applying the user-defined design value from the design criteria file). When stage temperatures are not available, the maximum value of temperature from all the inlet streams is used. • Number of Stages 6 Sizing Project Components 249 The number of theoretical stages is provided by the number of rows in Table 1. The final number is determined by taking into account condenser and reboiler (if they are provided). Also, the number of stages is affected by the reboiler type depending on whether the reboiler simulated in the report is kettle or thermosiphon. For example, in the case of RADFRAC model for AspenPlus, consider the following table: STAGE 1 2 3 4 5 6 7 8 9 10 TEMP. F PRESSURE PSI BTU/LBMOL LIQUID VAPOR HEAT DUTY BTU/HR 149.27 20.000 -0.12156E+06 -42602. -.23509+08 223.45 22.000 -0.11895E+06 -87138. 227.79 22.100 -0.11909E+06 -92519. 230.39 22.200 -0.11918E+06 -95701. 232.06 22.300 -0.11925E+06 -97662. 233.25 22.400 -0.11931E+06 -98970. 234.18 22.500 -0.11935E+06 -99924. 234.98 22.600 -0.11939E+06 -0.10068E+06 235.72 22.700 -0.11942E+06 -0.10135E+06 236.74 22.800 -0.11941E+06 -0.10196E+06 .45802+08 If the reboiler is kettle, then the number of theoretical stages is eight. If the reboiler is thermosiphon (reboiler type is obtained from simulator), then the number of theoretical stages is nine. • Liquid Density Density of liquid flowing inside the column is estimated from the density of the inlet streams and the exit streams. If liquid density cannot be obtained from the streams, the density of water is used as default. • Vapor Density Density of vapor flowing inside the column is estimated from the density of the inlet streams and the exit streams. If vapor density cannot be obtained from the streams, the vapor density is estimated based on gas law. The vapor density is estimated at the minimum operating pressure and operating temperature. • Average Molecular Weight of Vapor Inside Tower Average vapor molecular weight is estimated from the inlet and exit streams. The lowest molecular weight of the streams is assigned as the vapor molecular weight. • Average Molecular Weight of Liquid Inside Tower Average liquid molecular weight is the maximum molecular weight for the inlet and exit streams. Sizing Procedure The sizing procedure varies depending on the type of internals desired and the simulator model used for the operation. The procedure described below gives a description of the actual steps used by the sizing module to estimate the sizes for the different types of trayed and packed towers. 6 Sizing Project Components 250 Trayed Tower Sizing General Procedure (Followed for all tray internals): 1 The type (class) of the fluid in the column is used to estimate some of the properties in designing the tray internals, such as surface tension, foaming tendency, deration factor if they are not specified in the simulation output report or on the Design Criteria specifications form. You can specify the overall column tray efficiency in the Tray Efficiency box on the Design Criteria specifications form. If the value is not provided, then it is estimated using Lockett’s modification of the O’Connell Correlation. This correlation is based on tests on actual plant columns and has been the standard of the industry. The tray efficiency is used to calculate the actual number of stages required for the separation. EOC = 0.492 ( μL α) -0.245 where: EOC = efficiency, O’Connell Correlation μL = viscosity of liquid, CPOISE α = relative volatility of key component A default value of 1.5 is used for the relative volatility of key components that you can modify on the Design Criteria specifications form. The liquid viscosity is either directly obtained from the report or estimated from the fluid classification. • Once the internal height of the column is estimated (based on the actual number of trays), additional height for vapor disengagement and liquid return is based on your Design Criteria specifications. • In general, the number of stages provided by the simulator report represent the theoretical number of stages. However, if detailed design of the tower has been done by the simulator using tray efficiency, then the number of trays are actual trays. If Aspen Process Economic Analyzer finds that the number of trays are actual, then it uses the value to estimate the height and does not add any additional tray efficiency. Using Tower Sizing Information When a simulator report provides sizing information, Aspen Process Economic Analyzer tries to use as much of the information as possible in the final design. When multiple sections are present in the report, the information used by Aspen Process Economic Analyzer depends on the equipment to which the model is mapped. Single Diameter Trayed Tower (TW TRAYED) If multiple sections are present with different diameters and tray spacings, then the largest values of the diameters and tray spacings are used for the actual design of the tower. 6 Sizing Project Components 251 Double Diameter Trayed Tower (DTT TRAYED) For double diameter trayed tower, the two largest diameters in the sectional report are used in the design. Once the tower is divided into two sections (based on diameter), the value of the tray spacing for each section is based on the stage numbers present in each section. The largest values of tray spacing for each section are used to estimate the tower height. For example, for AspenPlus, assume the following sizing information is obtained from the report after completing the loading process. Section 1: Diameter = 5 FEET Tray Spacing = 24 INCHES Stages = 2 to 4 Diameter = 6 FEET Tray Spacing = 30 INCHES Stages = 5 to 7 = 8 FEET Section 2: Section 3: Diameter Tray Spacing = 18 INCHES Stages = 8 to 10 The sizing program will design a double diameter tower with the following dimensions: Top Section Diameter = 6 FEET Top Section Tray Spacing = 30 INCHES Top Section Stages = = 2 to 7 Bottom Section Tray Spacing = 18 INCHES Bottom Section Stages = 8 to 10 Bottom Section Diameter 8 FEET The program estimates the cross sectional area for each stage. Then, the maximum value is used to design the single diameter tower. In case of double diameter tower, the program estimates the diameter for the bottom section and the top section based on the cross sectional area estimated for each stage. 6 Sizing Project Components 252 Sieve Tray Design The capacity factor, CSB, is evaluated based on the correlation developed for entrainment flooding by Kister and Haas. Jeronimo et. al correlation is used to estimate the clear liquid height in the spray regime. Strictly, the Jeronimo and Swistowski correlation predicts the clear liquid height at the transition from the froth to the spray regime. However, empirical evidence has shown that clear liquid height in the spray regime is much the same as clear liquid height at that transition. The CSB estimated at the flooding point is used to evaluate the flooding vapor velocity. The bubbling area is calculated based on flood velocity, the derating factor and the safety factor. (Column default design is 90% of flood.) Downcomer liquid velocity is based on the foaming tendency of the fluid and tray spacing. Foaming tendency can be specified on the Design Criteria specifications form. The downcomer cross-sectional area is based on the downcomer velocity and the maximum liquid flow inside the tower. The total tower cross-sectional area is calculated by adding the bubbling area and the downcomer area. The diameter of the tower is obtained from the cross-sectional area by rounding the area up to the next half foot. The minimum diameter for the tower is 1.5 FEET. Valve Tray Design Valve tray sizing is based on the V-type Ballast trays produced by Glitsch. The system factors are estimated based on the fluid classification performed on the fluid flowing through the column. The tray diameter is evaluated for either single pass trays or two pass trays. It is based on 24 INCHES tray spacing and 80% of flood. Bibliography “Distillation Design”, by Henry Z. Kister. “Applied Process Design For Chemical And Petrochemical Plant”, Volumes 1 and 3, by Ernest E. Ludvig. “Standard Handbook of Engineering Calculations”, by Tyler G. Hicks “Chemical Engineers HandBook”, by Perry and Chilton, 6th Edition. Bubble-Cap Tray Design The allowable vapor velocity and the corresponding diameter for bubble-cap trays have been represented by the Jersey Critical formula which corresponds to the work by Souder and Brown for column flooding. ( D = 0.0956 Wv / K ρ L ρ v 6 Sizing Project Components ) 12 253 where: D = Diameter, FEET Wv = vapor flow rate, LB/H ρL ρv = liquid density, LB/CF = vapor density, LB/CF B B B B B B The factor K depends on the tray spacing as follows: Tray Spacing, INCHES K 18 3.4 24 4.2 30 4.7 30+ 5.0 Packed Tower Design Packed tower design is accomplished for both random and structured packings. The various types of packings supported by the system are described in the Icarus Reference. Kister and Gill flood point correlation is used to estimate pressure drop at the flood point as a function of packing factor alone. ΔΡFL = .155 (Fp0.7) where: ΔΡFL = Fp Pressure drop at flood point Packing factor Note: You can provide the value for the packing factor on the Design Criteria specifications form. The system defaults are used for each of the different types of packings if you do not enter a value. Once this pressure drop is known, the flood velocity is calculated using the latest version of GPDC (Generalized Pressure Drop Correlation) charts for both random and structured packings. HETP Prediction You can provide the HETP value on the Design Criteria specifications form. If the value is not specified, rules of thumb prediction reported in literature are used to predict the packed tower efficiency. For random packing columns, the following rules are used for estimating HETP (FEET): HETP dp 1.5 dp = = Packing diameter, INCHES for DT < 2 FEET HETP > DT For estimating the structured packing efficiency, the following rule of thumb is used: HETP, INCHES = 6 Sizing Project Components 1200 /ap + 4 254 ap = Packing surface area per unit volume, SF/CF System Defaults The following system default values may be modified on the Design Criteria specifications form and Component Specifications form: Trayed Tower Defaults Tray Type = Sieve Tray Spacing = 24 inches Flooding Factor = 80 % Foaming Tendency = Moderate Packed Tower Defaults Packing Type = Random Packing Material = 1.0PPR Specific area per unit volume for the packing = 0.75 SF/CF Top vapor disengagement height = 4 FEET Bottom sump height = 6 FEET General Defaults SimSci’s SHORTCUT Column Operation In case of SHORTCUT column operation, the simulator provides only the minimum reflux ratio for the distillation process. To design the tower, the ratio of the operating reflux ratio and minimum reflux ratio has to be provided. The system uses the default value of 2.0 for the ratio. The ratio can be changed on the Design Criteria specifications form. If the simulator report does not contain information (number of trays) for the operating reflux ratio, the tower sizing program returns to the system without performing sizing for the tower. Vessels Horizontal Vessels The following graphic shows a typical horizontal vessel. 6 Sizing Project Components 255 The following design variables are specified on the Design Criteria specifications form: • Residence Time • Process Vessel Height to Diameter Ratio • Minimum Vessel Diameter • Vapor/Liquid Separator Sizing Method • Average Liquid Particle Diameter • Design factor multiplier for disengagement velocity • Separation Factor • Vapor area /cross sectional area • Separation Factor Multiplier • Minimum Boot Length (used in Horizontal Vessel Design) • Minimum Boot diameter • Boot Leg Liquid Velocity Design Requirements The maximum number of exit streams is three; two of the streams can be liquid. Calculating Diameter Vessel diameter is based on the maximum allowable vapor velocity inside the separator, to reduce the liquid entrainment in the vapor. The following two methods are available in Aspen Process Economic Analyzer (chosen from the Design Criteria specifications) to obtain vapor velocity. • Liquid Entrainment Method • Particle size separation method. 6 Sizing Project Components 256 Calculating Vapor Velocity Liquid Entrainment Method The maximum allowable vapor velocity, to reduce liquid entrainment is obtained as a function of liquid and vapor density and the Separation Factor, which itself is a polynomial function of vapor and liquid density and vapor and liquid flowrates. The polynomial equation was based on 5% of liquid entrained in the vapor and is valid for the range (defined below) of 0.006 to 5.0. Aspen Process Economic Analyzer allows you to override the computed value of Separation Factor. W = l_mfr/v_mfr * sqrt (v_rho/l_rho) X = ln (SF) k_v = EXP(A + BX + CX^2 + DX^3 + EX^4) K = k_v * k_vm v_m = K * sqrt ((l_rho - v_rho)/v_rho) where: l_mfr = Light Liquid Mass Flow rate v_mfr = Vapor Mass Flow rate l_rho = Light Liquid Density v_rho = Vapor Density K = System Factor SF = Separation Factor k_v = Polynomial Function of SF k_vm = Separation Factor Multiplier A = -1.877478097 B = -0.8145804597 C = -0.1870744085 D = -0.0145228667 E = -0.0010148518 The above relation for Separation Factor is valid for a “W”(SF) between 0.006 and 5.0. If “W” falls outside the range, the sizing program gives a warning message and the limiting value of W is used to estimate Separation Factor. For example, if calculated value of W is 0.001, then the value used in the correlation is 0.006. If the calculated value of W is 10.0, then the value used in the correlation is 6.0. Particle Size Separation Method This method estimates the disengagement velocity of liquid bubble in the vapor space. The maximum allowable vapor velocity is determined as a percentage of the disengagement velocity. Liquid drops falling in gases appear to be spherical up to a Reynolds number of 100. Large drops (greater than 0.3125 INCHES) will deform, with a resulting increase in drag, and in some cases shatter. 6 Sizing Project Components 257 For estimating vapor velocity, the liquid bubbles are assumed to remain in spherical shape. The terminal settling velocity can be obtained for different flow conditions. For laminar flow (K < 3): v = g * (rho_l - rho_v) *(dp^ 2)/ (18.0 * mu_v) and for turbulent region: v = 1.74 (g * dp * (rho_l - rho_v) / rho_v)^0.5 K = dp * (g * rho_v * (rho_l - rho_v)/ (mu_v^2) )^0.33 v = disengagement velocity where: g = gravitational constan rho_l = liquid density rho_v = vapor density dp = liquid bubble diameter mu_v = gas viscosity (assumed to be 0.05 LB/FT/H) The design velocity is then estimated by the following equation: v_m = v*f v_m = disengagement velocity f = design factor multiplier for disengagement velocity v = disengagement where: Calculating vessel cross-sectional area Vapor cross sectional area is estimated based on the vapor velocity and the vapor volumetric flow. The vapor cross sectional area is divided by the ratio of vapor area/cross sectional area to get the total required cross sectional area. v_csa = v_vol/v_m t_csa = v_csa/r_vc v_csa = Vapor area v_vol = Vapor volumetric flow r_vc = Vapor area/cross sectional area t_csa = Vessel cross sectional area where: Estimate Vessel diameter based on vapor flow: 6 Sizing Project Components 258 D_v = sqrt ((t_csa * 4) /π) = Vessel Diameter based on vapor flow 3.14 where: D_v = Estimate vessel diameter based on liquid holdup volume and user-specified value of L/D ratio. The maximum value of diameter calculated using vapor velocity and liquid holdup is used for final design. Calculating Length Vessel liquid holdup volume is obtained based on the light liquid flowrate and the residence time. The vessel length is then calculated as given below: l_vol = l_vfr * r_t L = (l_vol * 4) / (π * D^2 * (1 - r_vc)) = Liquid holdup volume where: l_vol L = Length l_vfr = = = Light liquid volumetric flowrate r_t r_vc Residence time r_vc Checking L/D Ratio For all liquid vessels L/D is calculated as follows: If If 250 < If P <= 250 PSIA, P <= 500 PSIA, then L/D = 500 then L/D= P> then L/D= PSIA, 3 4 5 After estimating the length (L) and diameter (D) of the vessel, the ratio of L/D is compared with the Process Vessel Height to Diameter Ratio specified on the Design Criteria specifications form. Estimating Boot Dimensions Boot dimensions will be estimated only if the exit streams contain a heavier liquid phase. Boot diameter is based on the heavier liquid phase volume and boot liquid velocity. Boot volume (bt_vol) = hl_vfr * r_t Boot cross section area (bt_csa) = bt_vol / hl_vel 6 Sizing Project Components 259 Boot diameter (d) Boot length (l) = = sqrt (4.0 * bt_csa /π) (bt_vol * 4)/(π * d^2) where: hl_vfr = heavy liquid volumetric flow rate hl_vel = heavy liquid velocity l = boot length d = boot diameter Vertical Vessels The following graphic shows a typical vertical vessel. The following design variables are specified on the Design Criteria specifications form: • Residence Time 6 Sizing Project Components 260 • Process Vessel Height to Diameter Ratio • Minimum Vessel Diameter • Vapor/Liquid Separator Sizing Method • Average liquid particle diameter • Design factor multiplier for disengagement velocity • Separation Factor • Minimum Disengagement Height • Minimum height above the mist eliminator • Height of Mist Eliminator Vessel diameter is calculated in the same manner as for horizontal vessels. The default value of Separation Factor Multiplier is available in the Design Criteria specifications. Calculating Vessel Height Vessel liquid holdup volume is based on the light liquid flowrate and the residence time. The liquid height in the vessel is then calculated and the additional height is added to obtain the overall vessel height. l_vol = l_vfr * r_t l_ht = (l_vol * 4) / (π * D^2) h = LLLTap_ht + l_ht+ HLLTap_ht + d_ht + me_ht + mea_ht where: l_vol l_vfr = = light liquid volumetric flowrate r_t = residence time l_ht liquid height based on residence time LLLTap_ht = = ddHLLTap_ht = height between inlet nozzle and high liquid level tap (desig criteria) d_ht = = = disengagement height me_ht mea_ht liquid holdup volume minimum height between low liquid level tap and tangent line (design criteria) mist eliminator height Height above the mist eliminator If the calculated l_ht is less than the minimum height between the taps, specified in the design criteria, then the minimum height is used. Checking L/D ratio For all liquid After estimating the length (L) and diameter (D) of the vessel, the ratio of L/D is compared with the Process Vessel Height to Diameter Ratio specified on the Design Criteria specifications form. 6 Sizing Project Components 261 6 Sizing Project Components 262 7 Piping and Instrumentation Models Interconnecting Volumetric P&ID Lines Connect pipelines between components in a Aspen Capital Cost Estimator project, estimate the project, and create piping line list report for connected lines with the same line tag. Open an Aspen Capital Cost Estimator project Open a new or existing Aspen Capital Cost Estimator project, add equipment components to the new project. 7 Piping and Instrumentation Models 263 Run Interconnect Piping Lines To run interconnect piping lines: 1 On the main tool bar, click Run. 2 Click Interconnect Piping Lines to launch the GUI as shown below: The GUI displays five lists. All equipment and its associated pipelines in the project are displayed in two groups: • Connect From • Connect To The first two lists display equipment and piping lines in the Connect From group. The third list displays all connected lines. The fourth and fifth lists display piping lines and equipment in the Connect To group. 7 Piping and Instrumentation Models 264 3 On the list in the Connect From and Connect To groups, click the desired equipment item. The line lists will then display only the lines corresponding to the selected equipments. When the mouse hovers over an equipment or a line, the tooltip in the list provides additional information related to this item. The related additional information is also displayed in the bottom text area when clicking on an equipment or a line. Connecting Piping Lines To connect two lines: 1 Select the Auto Generate Line Tag check box, or, in the Line Tag field, type a unique line tag. 2 In the Connect From line list, click a piping line. 3 In the Connect To line list, click the desired line. 4 Click Connect. 7 Piping and Instrumentation Models 265 5 Repeat Steps 1-4 above to connect all the desired lines between the equipment items. Note: Use Filter to display all disconnected equipment or all disconnected lines. Disconnecting Piping Lines To disconnect all existing pipeline connections between all equipments: • Click Disconnect All. All connected lines will be removed from middle list and will be displayed in the respective line list. To disconnect a specific line between the two equipments: • In the middle list, click a line item; then click Disconnect. 7 Piping and Instrumentation Models 266 Renaming a Line Tag To rename a line tag: 1 On the Connecting list, click the desired item. 2 In Line Tag field, edit the line tag. 3 Click Rename Line Tag. 7 Piping and Instrumentation Models 267 Saving All Connections and (optionally) Updating the Project To save all the connections and update the project: • Click the Update Project. To save all the connections without updating the project: • Click the Save Mapping & Exit. All connections on the GUI are saved, but the project is not updated. Getting the Connected Line List Report To get the connected line list report: 1 Evaluate the above project. 2 Click View | Capital Cost View. The Select Report Type to View dialog box appears. 3 On the Select Report Type to View dialog box, click Interactive Reports; then click OK The reporter is active. 4 Click Excel reports. 5 Click Other reports | Discipline | Pipe: o Connected Line List -or- o Model Line List as shown below: 6 Click Run Report. 7 Piping and Instrumentation Models 268 The report is shown below: Connected Line List Model Line List Mapping Streams to Piping Lines Note: For Aspen Capital Cost Estimator with Aspen Process Economic Analyzer Overlay project, see the Aspen Process Economic Analyzer user guide (AspenProcessEconAnalyzerV7_0-Usr.pdf). In an existing or new Aspen Process Economic Analyzer (or Aspen Capital Cost Estimator with Aspen Process Economic Analyzer Overlay) project, you can assign stream physical properties to lines in order to size the line diameter. To Map Streams to Lines: 1 Open an existing Aspen Process Economic Analyzer or Aspen Capital Cost Estimator (with Aspen Process Economic Analyzer overlay) project, or create a new project. 2 On the main menu, click Run | Map Stream to Lines to launch the GUI. 7 Piping and Instrumentation Models 269 The GUI displays four lists. All the streams are displayed in the STREAM list box. All equipments and their associated pipelines in the project are displayed in the last two list boxes. The middle list displays all mapped streams and lines. 3 On the Equipment list, click an equipment item. The line list will then display only the lines corresponding to the selected equipment. When the mouse hovers over an equipment or a line or a stream, the tooltip in the list provides additional information related to this item. The related additional information is also displayed in the bottom text area when clicking on an equipment item, a line, or a stream. 7 Piping and Instrumentation Models 270 Mapping Streams to Piping Lines To map a stream to a pipeline: 1 On the STREAM list, click a stream. 2 On the Aspen Capital Cost Estimator | Line list, click a piping line. 3 Click Map. Mapped streams and lines are displayed in the middle list. 4 Repeat steps 1-3 above to map all the desired streams and lines. Note: Use Filter to display all unmapped equipment and all unmapped lines if needed. Un-mapping Streams to Piping Lines To Un-map all existing mapped streams and lines: • Click Un-map all. 7 Piping and Instrumentation Models 271 To Un-map a specific stream and line: 1 On the Mapping list, click a mapped item. The Map button becomes Un-Map. 2 Click Un-Map. The selected items are removed from the middle list and go back to their respective lists. Using the Auto-Map Option You can set the Auto-Map option in two ways: • On the Preference tab • From the Mapping GUI To use the Auto-Map Option using the Preference tab: The Auto Map button will be unavailable in the mapping GUI if on the Tools | Options | Preferences | Process tab the Auto Map Streams to Lines check box is selected. The Pre-auto-mapped streams-lines will be displayed in the middle list box of the Map Stream to lines GUI. 7 Piping and Instrumentation Models 272 To make the Auto Map button available: • On the Tools | Options | Preferences | Process tab, clear the Auto Map Streams to Lines check box. To use the Auto-Map Option from the Mapping GUI: • On the Map Stream to Lines dialog box, click Auto Map to automatically map streams to lines. To save all the stream mappings to lines and update the project: • Click Update Project. 7 Piping and Instrumentation Models 273 To save all the stream mappings to lines without updating the project: • Click Save Mapping & Exit. 7 Piping and Instrumentation Models 274 7 Piping and Instrumentation Models 275 8 Developing and Using Cost Libraries The Libraries view on the Palette arranges libraries in a tree-structure. Most of the libraries listed access project specifications (explained in Chapter 3). The Cost Libraries are unique, however, in that they comprise collections of particular cost items that you can add as project components. The cost libraries are customizable; you can add items to the libraries provided, as well as add your own libraries. Aspen Process Economic Analyzer includes two types of cost libraries: Equipment Model Library (EML) and Unit Cost Library (UCL). Each library type may include one or more library files, which in turn may contain one or more library items, each representing a particular type of cost item. Equipment Model Library (EML) The EML is intended to store custom equipment items, for which you create component specification forms. In a project, you can add an item from the EML as a component and fill out the form that you earlier created. The library can store a generic equipment item that comes in discrete sizes, such as an extruder, or an equipment item that follows a continuous cost-capacity relationship such as linear, semi-log or log-log. Unit Cost Library (UCL) The UCL is intended to store and retrieve direct costs and installation man-hours, which are based on a simple unit of measure (for example, the cost of a material item or installation man-hours per unit of area, per unit of length, per item, etc.). Costs can also be stored in a library for indirect items such as project management man-hours per month, crane rental (plant hire) on a daily, weekly, monthly basis, etc. 8 Developing and Using Cost Libraries 276 For one-of-a-kind cost items not worth storing in a library, the unit cost library may be used to create a dummy item for recall and modification in a project. The dummy item is stored in the library with as little data as possible. This can be retrieved and modified in as much detail as required whenever you need a one-time cost added into a project. Developing and Using an Equipment Model Library (EML) Creating an EML The instructions in this sub-section show you how to create an EML. The instructions in the sub-sections that follow this one, which show you how to add an item to an EML and then add the item to a project, use a single example that can be added either to an Inch-Pound EML that you created or to one of the two Inch-Pound EML’s provided. To create an EML: 1 With no project open, go to the Palette’s Libraries tab view. 2 Expand Cost Libraries in the tree-structure, and then expand Equipment Model Library. The libraries are divided into Inch-Pound and Metric. 3 To create a library for use in projects with an Inch-Pound units of measure basis, as in the example used in these instructions, right-click InchPound; then click New on the pop-up menu. The New Equipment Model Library dialog box appears. 8 Developing and Using Cost Libraries 277 4 Enter a file name (required) for the EML and a brief description (optional), then click OK. An empty Library dialog box appears. You can now add items to the new library. Adding an Item to an EML The instructions below for defining and using an EML item follow a single example from item creation through the addition of the item to a project. Using the example provided will define the item in such a way that it automatically generates a foundation and/or electrical power supply bulks. To add an item to an EML: Note: If you just added a library, the Library dialog box is displayed, and you can skip to Step 2. If not, follow these steps: 1 Go to the Palette’s Libraries tab view. 8 Developing and Using Cost Libraries 278 2 Expand Cost Libraries, Equipment Libraries, and either Inch-Pound or Metric. (If following the example provided, select Inch-Pound.) 3 Right-click on the library to which you want to add an item, and then click Modify on the pop-up menu. 4 Click Add on the Library dialog box. 5 Enter a Reference ID for the item in the Add Item dialog box. The one- to six-character alphanumeric Reference ID uniquely identifies the library item being added. The ID is used to sort and search for library items. The first character must be a letter. 6 Click OK. 7 Enter the descriptive data for a the item in the Develop Equipment Model Library form. If following the example, enter the data exactly as shown below. Be sure to correctly enter the sizing parameters, CAPFLOW and PWRDRVR; Aspen Process Economic Analyzer knows to use GPM (or L/S for METRIC) and HP, respectively, for these parameters. Sizing method: the data is in the form of either a continuous curve (linear, log-log or semi-log) or a set of discrete tabular values. When an equipment model library item is retrieved into a project, the specified size for the project component is used to develop the appropriate cost, man-hours and weight from the library data. 8 Developing and Using Cost Libraries 279 8 Click OK to save your specifications. The new item appears on the Library dialog box, which you can now close. Adding an EML Item to a Project Scenario To add an EML item to a project scenario: 1 Open the project to which you want to add the EML item. For the purposes of this example, you can use either an existing or newly created US/I-P based project. 2 In Project Explorer (Project view), right-click on the area in which to add the EML item, and then click Add Project Component on the pop-up menu. 3 On the Icarus Project Component Selection dialog box, specify a project component name for the item. 4 Click Equipment Model Library and click OK. 5 On the Select an Equipment Model Library File dialog box, click the EML to which you added the item; then Click OK. 6 On the Select an Equipment Model Library Item dialog box, select the item you added; then click OK. 8 Developing and Using Cost Libraries 280 7 Enter your specifications for the item at the Component Specifications form, as shown below. Note that the Size parameters CAPFLOW and PWRDRVR are included on the form. 8 Click OK to apply and save the specifications. The item will now be included in project evaluations. Developing and Using a Unit Cost Library (UCL) The instructions below use as an example a library of asbestos abatement (ASBABT) costs and man-hours. This example has been selected because environmental remediation data is difficult to model, since costs and 8 Developing and Using Cost Libraries 281 man-hours tend to vary greatly based on site conditions and project types. Items of a unique and/or variable nature are ideal for storing in a UCL. The instructions take this example through the following stages: library creation, adding items to the library, adding a library item to a project as a component, and forming an assembly in the project out of multiple UCL items. Creating a Unit Cost Library To create a unit cost library: 1 With no project open, go to the Palette’s Libraries tab view. 2 Expand Cost Libraries in the tree-structure, and then expand Unit Cost Library. The libraries are divided into Inch-Pound and Metric. 3 To create a library for use in projects with an Inch-Pound units of measure basis, as in the ASBABT example used in these instructions, right-click on Inch-Pound and click New on the pop-up menu. 4 In the New Unit Cost Library dialog box, enter a file name (required) for the UCL and a brief description (optional). 8 Developing and Using Cost Libraries 282 5 Click OK to create the new UCL. An empty Library dialog box appears. You can now add items to the new UCL. Adding an Item to a UCL To add items to a UCL: 1 If you just added a library, the Library dialog box is displayed, and you may skip to Step 2. If not, follow these steps: a. Go to the Palette’s Libraries tab view. b. Expand Cost Libraries, Unit Cost Libraries, and either Inch-Pound or Metric. c. Right-click on the library to which you want to add an item, and then click Modify on the pop-up menu. 2 Click Add on the Library dialog box. 3 Enter a Reference ID for the item in the Add Item dialog box. 8 Developing and Using Cost Libraries 283 The one- to six-character alphanumeric Reference ID uniquely identifies the library item being added. The ID is used to sort and search for library items. The first character must be a letter. 4 Click OK. 5 In the Develop Unit Cost Library form, enter information for the new item. Note: Costs for the item will be allocated to the specified Code of Account (COA). See ICARUS Reference, Chapter 34, for COA definitions. Aspen Process Economic Analyzer uses the Material Cost Per Unit and Labor Cost Per Unit to cost the item in an estimate. If Labor Hours Per Unit is specified and Labor Cost Per Unit is left blank, Aspen Process Economic Analyzer will calculate the labor cost using the project wage rates at the time of the estimate. The Unit of Measure can be designated for “each” or by any appropriate unit (i.e., “1000 SF” ). Be sure to sufficiently describe the item so that you know what the unit costs include when the item is retrieved at some future date. The quantity is entered when the library item is retrieved into a project. The Date and Source are for your reference and are not transferred into an estimate. 6 When done entering specifications for the item, click OK. To add a set of items as in the ASBABT example, repeat the process (Steps 2-4) to add the following items in addition to the one shown in the previous graphic. Reference No. Item Description 8 Developing and Using Cost Libraries Code of Account Mat’l Cost Per Labor Cost Unit of Unit Per Unit Measure Date of quotation 284 AAB200 Polyethylene Sheeting 800 .021 AAB201 Duct Tape ( 300’ roll ) 800 AAB202 Adhesive Spray (60’ / can) AAB300 Decontami- .004 SF 04APR01 3.50 ROLL 04APR01 800 6.00 CAN 04APR01 800 300.00 2 EACH 04APR01 300.00 2 EACH 04APR01 .01 EACH 04APR01 nation Shower AAB301 Neg Air Pressure System 800 AAB400 Lighting Fixture Removal 800 After the above are added, the Library dialog box will appear as shown below. 7 When done adding items to the UCL, click Close on the Library dialog box. Adding a UCL Item to a Project To add a single UCL item to a project: 1 Open the project to which you want to add the UCL item. To add an item from the ASBABT library developed as an example in the previous instructions, you can open either an existing or newly created US/I-P based project. 2 In Project Explorer (Project view), right-click on the area in which to add the UCL item, and then click Add Project Component on the pop-up menu. 3 On the Icarus Project Component Selection dialog box, specify a project component name for the item. 8 Developing and Using Cost Libraries 285 4 Select Unit Cost Library and click OK. 5 On the Select a Unit Cost Library File dialog box, select the UCL to which you added the item and click OK. 6 On the Select a Unit Cost Library Item dialog box, select the item you added and click OK. 8 Developing and Using Cost Libraries 286 7 On the Component Specifications form, click the Option drop-down button and click Unit Cost Items. Aspen Process Economic Analyzer retrieves the unit cost data you set up in Libraries. Creating an Assembly of UCL Items This section shows how to add several items from the library to form an assembly. In the example, the items from the ASBABT library are added to form an Asbestos Abatement Area Preparation Assembly. To create an assembly of UCL items in a project: 1 In Project Explorer (Project view), right-click on the area in which to add the UCL item, and then click Add Project Component on the pop-up menu. 8 Developing and Using Cost Libraries 287 2 On the Icarus Project Component Selection dialog box, enter as the project component name a description of the assembly. 3 Click Unit Cost Library and click OK. 4 At the Select a Unit Cost Library File dialog box, select the UCL containing the first item to add to the assembly and click OK. 5 At the Select a Unit Cost Library Item dialog box, select the first item to add to the assembly and click OK. 8 Developing and Using Cost Libraries 288 6 On the Component Specifications form, click the Option drop-down button and select Unit Cost Items. 7 Click Add. 8 On the Select a Unit Cost Library File dialog box, select the UCL containing the next item to add to the assembly and click OK. 9 On the Select a Unit Cost Library Item dialog box, select the next item to add to the assembly and click OK. 8 Developing and Using Cost Libraries 289 10 Repeat the process of adding items until the form contains columns for all the items in the assembly. 11 After entering quantities for the items click OK. The assembly is listed as one project component on the Project Explorer (Project view) and the List view. You can now run an evaluation on the item (see page 462 for instructions). An Item Report would summarize total costs and man-hours, as well as list each assembly item’s costs and man-hours. 496H 8 Developing and Using Cost Libraries 290 Working with Cost Libraries Equipment model and unit cost libraries share the functions described in this section. Copying a Library Item When adding a library item similar to one that already exists, it is easier to copy the existing library item and modify the necessary specifications. To copy a library item: 1 Highlight a library item in the Library dialog box and click Copy. 2 Enter a Reference ID for the new item. The one- to six-character alphanumeric Reference ID uniquely identifies the library item being added. The ID is used to sort and search for library items. The first character must be a letter. 3 Click OK. Aspen Process Economic Analyzer adds the new item with all the same data as the original — only the Reference ID has changed. Deleting a Library Item When a library item is no longer useful, it can be removed from the library file. To delete a library item: 1 Highlight a library item in the Library dialog box and click Delete. A dialog box appears to confirm the delete. 2 Click Yes to delete the selected library item. -orClick No to retain the library item in the library file. Escalating Library Costs Library items contain costs which change over time due to inflation. Escalating library costs bring the library costs up to date. To escalate library costs: 1 Click Escalate on the Library dialog box. 8 Developing and Using Cost Libraries 291 The Escalate Costs dialog box appears. 2 Enter the escalation specifications. In this field type New Base Date: The date of escalation or the date at which the prices are current. Material Escalation: Amount by which to escalate material costs. Labor Escalation: Amount by which to escalate labor costs. Since equipment model libraries only include setting man-hours, not labor costs, this field only appears when escalating unit cost libraries. 3 Click OK to escalate all the library items in the library file. Importing a Cost Library You can import UCL files, which have the extension “.LIB”, and EML files, which have the extension “.EML”, from elsewhere on your computer or network. To import a cost library: 1 In the Palette (Libraries view), right-click on the appropriate Units of Measure basis (Inch-Pound or Metric), and then click Import on the pop-up menu. 8 Developing and Using Cost Libraries 292 2 In the Select a File for Import window, locate the file and then click Open. The file is now included in the Palette and its items can be added as Aspen Process Economic Analyzer project components. Duplicating a Cost Library To duplicate a cost library: 1 In the Palette (Libraries view), right-click on the library you wish to duplicate, and then click Duplicate on the pop-up menu. 2 Enter a file name and description (optional) for the new library. 8 Developing and Using Cost Libraries 293 Aspen Process Economic Analyzer displays the Library dialog box for the new Library, which contains the same items as the original. You can add, modify, or delete the items without affecting the original. Deleting a Cost Library To delete a cost library: • In the Palette (Libraries view), right-click on the library to be deleted, and then click Delete on the pop-up menu. 8 Developing and Using Cost Libraries 294 9 Changing Plant Capacity and Location Two modules within Aspen Process Economic Analyzer, Analyzer Scale-up Module (ASM) and Analyzer Relocation Module (ARM) let you evaluate alternate plant capacities and locations. Analyzer Scale-up Module (ASM) When you change plant capacity, Analyzer re-sizes each project component to your desired plant capacity. Unique expert system rules, based on engineering principles, provide the basis for revising the size of every project component in the process facility that is implicated in stream flows, as well as the size of other plant facility components in the plant layout, including process and utility components inside battery limits (ISBL) and outside battery limits (OSBL), associated installation bulks, piping, cable runs, buildings, structures, pipe racks, and site improvements. Quoted costs and installation hours, and in some instances, numbers of identical items (for example, the number of trees along a fenceline) are also subject to change on changing production capacity. Changing Plant Capacity Changing the production capacity affects not only every stream flow, but the size, and in some cases, the number of project components. The Analyzer Scale-up Module (ASM) automatically examines each element of a project, applies a set of scale-up rules unique to that element and recreates the entire plant description according to the new production capacity. ASM contains rules for each of the hundreds of Aspen Icarus project components. Rules are based on engineering principles for elements that are directly linked to production capacity. For other elements that are footprint oriented such as building and structures, rules based on heuristics are applied. When the scaled project is evaluated, design quantities that are developed for the newly sized components are designed to meet the needs of a project. Further, revisions to P&IDs and similar user adjustments contained in the baseline project are also treated in the same way. The idea is to design a scaled project as it is intended to be built. This methodology eliminates the 9 Changing Plant Capacity and Location 295 need for applying a factor to the baseline plant cost to scale it up or down. Given a new capacity, ASM recreates the entire plant. The ASM process is automatic and rapid. ASM revises sizes of components to meet a revised capacity and the project evaluation engines do the difficult, time-consuming evaluation work. Users find ASM performs its re-sizing operation results to be similar to engineering design methods with the added benefit of much reduced time and resources. Further, equal confidence can be applied to evaluation results before and after using ASM as rules are discipline-based and the before and after evaluation processes are identical. To change plant capacity: 1 Open your baseline project and save it under a new scenario name that reflects the new capacity. This will ensure that your baseline project remains intact, separate and apart from your about-to-be scaled project. 2 On the Run menu, click Decision Analyzer or click the “A” button on the toolbar. The Decision Analyzer dialog box appears. 3 Select the Change Plant Capacity by (5-600%) check box. 4 Enter the desired percentage adjustment or select it using the Up/Down arrow buttons. For example, if you need to revise the capacity by a value 9 Changing Plant Capacity and Location 296 beyond 600% to 700%, scale your project twice. For this, the Evaluate Project check box should be cleared. Then you can split the desired 700% into two parts: first use 350%, and on completion, scale it again at 200%. 5 Click OK to initiate the Analyzer Scale-up Module. 6 Upon completion, save the scaled project. Analyzer Scale-Up Module (ASM) How ASM Works Scale-up of a project to a new production capacity is a two-step process. 1. The Aspen Scale-up Module is invoked. The ASM processor (a) analyzes each specification in your project (b) applies the appropriate scale-up rule (c) revises the specification to a new value (d) moves on to the next specification You can follow the progress of this phase by noting the item names in the display at the bottom of your screen. 2. The project is evaluated. This phase performs the designs, develops quantities, hours, costs, etc., and prepares the basic set of reports for your project at the new capacity. On completion of this step, you can proceed to prepare special reports and perform other analyses on your newly scaled project. Save the project after the scale-up operation. Scale-Up Rule Set Analyzer contains rules for hundreds of components and cost elements that are based on: • engineering design principles for scale-up of all process equipment, stream flows, quoted costs and hours, and so on. • heuristics for plant items that are based on footprint and plot plan The current rule set in some instances modifies the number of items rather than change sizes, as in the simple example of trees along a fence line, where the number of trees would be revised rather than the size of each tree. In the current rule set, there is no automatic provision for changing the number of project components. 9 Changing Plant Capacity and Location 297 Limiting Conditions It is possible that on extreme capacity scale-ups, sizes of certain equipment or bulk items may surpass a system limiting value. In this case, an error condition would be issued. The user would then examine the scaled model for the particular item(s) and revise the size and number of out-of-range items accordingly, as an item in an error condition would be excluded from the estimate. Scale-up Candidates ASM rules apply to the following types of project information: 1 Area specs: distances, dimensions, cost per unit weight 2 Project Component specs: specific rules based on item type and specification, typically size dimension, capacity, power and occasionally number of items Note: Several sanitary process equipment items associated with batch food processing are not scaled. 3 Installation specs: quoted costs, hours and numeric dimension specs for piping, duct, civil, steel, electrical, insulation, paint. Text-based sizes such as pipe schedule, wire size, etc. are symbolic and are not scaled. 4 Project Component Quoted Cost and Hours: While ASM has rules for quoted cost and hours, the ASM rule may not be the best for your type of item. Here, it’s better to apply a % Adjustment to the system’s estimated cost in an amount that will bring the estimated cost up to your quoted value. Then, on scaling, the new reported cost will be calculated by applying your % Adjustment to the estimated cost. Based on the scaled sizes. o Quoted hours: based on item type o Quoted weight: based on item type o Stream flow rate: scaled to the new capacity Scale-Up for Configuration Analysis Often, sections of a proposed facility may be required to consist of parallel trains, joining up to meet downstream units. Situations such as these are best handled by creating models of these sections at a standard capacity and then scaling desired sections to say 50% capacity. You would then import the various sections into an overall model, with multiple trains being imported as many times as required. The resulting model would then be evaluated for capital investment and process economics. Analyzer Relocation Module (ARM) The Analyzer Relocation Module lets you evaluate the impact of worldwide location on capital cost and a variety of other econometrics. Specifically, you 9 Changing Plant Capacity and Location 298 can “relocate” a project from one base location to any one of 89 worldwide locations. You can choose to retain the location of your engineering workforce or choose any one of 89 worldwide locations. When you need to evaluate a project that you might engineer and/or construct in a different city or country location, ARM will quickly and automatically revise your project parameters with those contained in its location knowledge base. The ARM knowledge base includes key locationdependent data and rules to convert your project from its starting base location to your selected location using location dependent values for design parameters, engineering and construction work forces, cost of materials, and engineering, material and construction indirects. You can use ARM in combination with the Analyzer Scale-up Module (ASM) and Analyzer Economics Module (AEM) all in the same run or separately from the other modules. Relocation Terminology • Baseline project: initial case, before executing ARM. • Relocated project: after ARM processing of the baseline project. • Relocation: a process of evaluating an initially formulated project (baseline project) to a new location (relocated project). • Locations: a general location, characterized by a city and country name, which is used to represent a particular EPC function. The function may or may not be physically sited in that city. • Engineering location: city and country name used to characterize the engineering workforce assigned to the project. • Plant location: city and country name used to characterize the plant site. Workflow The figure below shows the general work process. ARM specs, contained in the ARM rule set are applied to the user’s model. A description of the elements in the table is provided in the section following the Workflow. 9 Changing Plant Capacity and Location 299 How the Analyzer Plant Relocation Module (ARM) Works Relocation Reports For New Engineering and Plant Location Baseline Reports For Base Engineering and Plant Location U U Baseline Project Analyzer Project Relocation Module (ARM) Relocated Project ARM Specs Project Specs Construction Hours Construction Rates Material Quantities Engineering Hours Engineering Rates Construction Indirects Materials Indirects Engineering Indirects Construction Contingency Materials Contingency Engineering Contingency Construction Fee Construction Cost Engineering Cost Material Cost Project Contingency 9 Changing Plant Capacity and Location 300 1 Since ARM processing is automatic, it is wise to first save your base project under a new scenario name in advance of running ARM. Use a scenario name that refers to the planned new capacity. This will ensure that your baseline project remains intact for further evaluations. 2 On the Run menu, click Decision Analyzer or click the “A” button on the button bar: Figure 1. Button Bar This will display the Decision Analyzer dialog box, Figure 2. Note: ARM shares space with ASM and AEM and Evaluate Project on the four-part Decision Analyzer dialog box. 3 Select the check box Change Plant Location to. 4 Click the Plant Location from its pull-down list. 5 Click the Engineering Location from its pull-down list. 6 Use the remaining check boxes to select options to: o Enable escalation for Aspen Process Economic Analyzer projects. o Retain your defined construction start date and duration. If unchecked, a new date will be developed on relocation. Note: The last line on the Decision Analyzer dialog box displays three pieces of information: • plant location • currency name • currency symbol, in parentheses This information is a reminder to users of the Analyzer Economics Module (AEM) who are interested in reporting costs in currency different from the plant location currency. For this, two entry slots are provided for an exchange rate and symbol. If AEM is not invoked, values so entered will not affect the reporting aspects of relocation aspects. In Figure 2, the user elected to run AEM. This would take place immediately after ARM completed the relocation process, described as follows. Figure 2. Decision Analyzer Dialog Box – Illustration for a plant to be engineered in Rotterdam and constructed in Singapore. The currency of the plant location is displayed in the last wire-frame. 9 Changing Plant Capacity and Location 301 Figure 2. Decision Analyzer Dialog Box Relocating the Project 7 Having completed the choices, click OK to run the project. If you click Cancel, all choices will be ignored and control will return to the explorer view. With your OK, Decision Analyzer’s relocation module will automatically convert your base location project to the selected engineering and plant location. Your project will then contain the results of the relocation, which you can review and modify. To do this, select the Project Basis view and click on the desired basis category. Open the associated form, review the data and modify, as you desire. When pleased with the results, SAVE the project, making sure that it is saved under a scenario name that describes the relocation and most important, that your baseline project is not disturbed by the SAVE. You can then evaluate the project and review the results. A final SAVE will save the results. 9 Changing Plant Capacity and Location 302 ARM Knowledge Base The ARM knowledge base consists of approximately ten thousand locationspecific data values plus rules that govern the way the location data will be applied to your baseline project. The ARM knowledge base is derived from a variety of qualified sources including: • Aspen Richardson international construction data: raw data from this source (also used to prepare the Aspen Richardson International Cost Factor Manual) were analyzed and mapped into Icarus technology formats for use in ARM • Proprietary sources • Practicing professionals, EPC and owner customers and associates • Surveys • Technical publications that specialize in international construction costs • Government sources: seismic, climate data and other location data • Financial sources: exchange rates, etc. • Aspen Icarus models: to blend and fill in sparse data areas Five Bodies of Data The ARM knowledge base consists of five bodies of data: • Location specs • Project specs • Engineering specs • Construction specs • Material Cost specs Highlights of each component follow. Location Specs ARM is formulated for 89 locations in 33 currencies. Locations listed below include the four Icarus country base locations. The locations are similar to those in the Aspen Richardson International Cost Factor Manual list. Locations are organized and sorted by continental region, country and city. For Canadian and US locations, names include state, province or territory. Conventional short forms of country and city names are used for simplicity. • Regions - The number of locations for each region is listed in Table 1. • City Locations outside the US are listed in Table 2 • US locations are listed in Table 3. TABLE 1. List of Locations in Each Region Africa 3 Asia 15 Australia 3 Canada 6 Central America 2 9 Changing Plant Capacity and Location 303 Europe 12 Middle East 6 South America 5 United States 37 All Locations 89 Non-US Locations 52 TABLE 2. List of Non-US Locations Region City, Country Near Africa El Hassania, Morocco Casablanca Ibadan, Nigeria Johannesburg, South Africa Asia Beijing, China Guangzhou, China Shanghai, China Bhopal, India New Delhi Mumbai (Bombay), India Jakarta, Indonesia Kobe, Japan Tokyo, Japan Kuantan, Malaysia Kuala Lumpur Manila, Philippines Singapore, Singapore Seoul, South Korea Taipei, Taiwan Australia Samutprakam, Thailand Bangkok Binh Duong, Vietnam Hanoi Melbourne, Australia Perth, Australia Sydney, Australia Central America Guatemala City, Guatemala Mexico City, Mexico Canada Calgary, Canada Montreal, Canada Toronto, Canada Vancouver, Canada Windsor, Canada Winnipeg, Canada Europe Brussels, Belgium Paris, France Frankfurt, Germany Dublin, Ireland Milan, Italy 9 Changing Plant Capacity and Location 304 Amsterdam, Netherlands Rotterdam, Netherlands Warsaw, Poland Moscow, Russia Barcelona, Spain London, United Kingdom Manchester, United Kingdom Middle East Cairo, Egypt Kuwait City, Kuwait Dammam, Saudi Arabia Al Jubail Jeddah, Saudi Arabia Gebze, Turkey Istanbul Abu Dhabi, UAE South America Buenos Aires, Argentina Rio de Janeiro, Brazil Medellin, Colombia Lima, Peru Caracas, Venezuela TABLE 3. List of US City Locations Anchorage, AK Atlanta, GA Baltimore, MD Boston, MA Cape Girardeau, MO Cayey, PR Charlotte, NC Chicago, IL Cincinnati, OH Dallas, TX Denver, CO Fairbanks, AK Green Bay, WI Houston, TX Huntsville, AL Indianapolis, IN Kansas City, MO Knoxville, TN Las Vegas, NV Los Angeles, CA Louisville, KY New Orleans, LA New York, NY Newark, NJ 9 Changing Plant Capacity and Location 305 Oakland, CA Philadelphia, PA Phoenix, AZ Portland, ME Portland, OR Sacramento, CA San Francisco, CA Seattle, WA Sherman, TX Spartanburg, SC St Louis, MO Syracuse, NY Wilkes-Barre, PA Project Data The ARM knowledge base contains a comprehensive set of values for project level data. These should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site. • Currency: Exchange rate (FEX), as of the first day of the basis year, with exchange rate and currency units scaled to meet Icarus currency formats. Scaled currency units are provided at three levels: 3-character symbol, 8character name and 24-character description. Values are listed in Table 4. o Currency: 33 currencies are defined; some ARM locations share the same currency o Exchange rate, for each location. The ARM knowledge base works with exchange rates relative to the currency of each of the four country bases (US, UK, JP, EU). The currency table contains the rates as of the listed date. o Exchange rates are scaled in size to conform with Icarus exchange rate formats (0.01 to 99.9 in value) o Scaled currency symbols, names and descriptions are defined to conform to Icarus format; these contain symbols such as K to represent thousands and M to represent millions of scaled currency units, as indicated in Table 4. TABLE 4. List of Currencies Country Currency Description Currency Name Currency Symbol Exchange Rate, per USD (1 Jan 2006) Argentina Argentine Peso Peso-A P 3.0459 Australia Australian Dollar Dollar-A A$ 1.3644 Brazil Brazilian Real Real R 2.3517 9 Changing Plant Capacity and Location 306 Canada Canadian Dollar Dollar-C C$ 1.1641 China Chinese Yuan Renminbi Renminbi R 8.0755 Colombia K Colombian Peso K Peso K-P 2.28393 Egypt Egyptian Pound Pound-E PDE 5.786 European Union Euro Euro EUR 0.8446 Guatemala Guatemalan Quetzal Quetzal Q 7.615 India Indian Rupee Rupee R 45.195 Indonesia K Indonesian Rupiah K Rupiah K-R 9.85222 Japan K Japanese Yen K Yen K-Y 0.117681 Kuwait Kuwaiti Dinar Dinar DK 0.2921 Malaysia Malaysian Ringgit Ringgit R 3.7837 Mexico Mexican Peso Peso-MX P 10.66485 Morocco Moroccan Dirham Dirham-M D 9.3661 Nigeria K Nigerian Naira K Naira K-N 0.1305 Peru Peruvian Nuevo Sol NuevoSol NS 3.422 Philippines Philippine Peso Peso-P P 53.14 Poland Polish Zloty Zloty Z 3.255 Russia Russian Rouble Rouble RBL 28.75 Saudi Arabia Saudi Riyal Riyal R 3.7503 Singapore Singapore Dollar Dollar-S S$ 1.6642 South Africa South African Rand Rand ZAR 6.3359 South Korea K South-Korean Won K Won K-W 1.0287 Taiwan Taiwan Dollar Dollar-T T$ 33.147 Thailand Thai Baht Baht B 41.0767 Turkey Turkish New Lira New Lira NL 1.34979 United Arab Emirate Utd. Arab Emir. Dirham Dirham-U D 3.6732 United Kingdom British Pound Pound-UK PDS 0.5802 United States US Dollar DollarUS USD 1 Venezuela K Venezuelan Bolivar K Boliv K-B 2.15 Vietnam K Vietnamese Dong K Dong K-D 15.904 Current European Union Locations: • Belgium • France • Germany • Ireland • Italy • Netherlands • Spain 9 Changing Plant Capacity and Location 307 Note: Certain combinations of location currencies and country base currencies may result in exchange rates that exceed the format bounds for exchange rate. In such cases, ARM will automatically scale the exchange rate ratio and revise the currency units, usually with a prefix of "K" to indicate thousands of the above-listed currency unit. Example: The exchange rate for Plant location: India, at 45.145 per USD and Country Base: Japan at 0.1177 is 385.85 R/K Yen, which is beyond the exchange rate bound: the resulting ratio will be scaled by 1000 to 0.38585 KRupee/K Yen, and costs will be reported in KRupee (KR) • Equipment: design code (ASME, BS5500, DIN, JIS depending upon the plant location) • Civil and Steel: seismic acceleration, soil, footing depth, low/high ambient temperatures, wind velocity, hand excavation • Electrical: power supply frequency • Equipment Rental: a Construction Technology Level (CTL) parameter (L, M, and H) is assigned to each location. Locations assigned as H-level draw from the entire system slate of equipment rental items. S-level locations select from a smaller slate than M-level locations. • Use of gin poles vs. heavy cranes: each location is assigned a value for the heavy lift option Engineering Work Force The ARM knowledge base contains a comprehensive set of engineering workforce values, which should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site. The following are provided by ARM for each engineering work force location: • Hourly rates for each of 77 disciplines in the engineering workforce slate. Hourly rates are provided in the currency of the engineering location. During the processing of a project, these rates are converted, for consistent cost reporting, to the currency of the plant location using the exchange rate ratio: Discipline Rate in Plant Location Currency = Discipline Rate in the Engineering Location Currency x Plant Location Exchange Rate / Engineering Location Exchange Rate • Engineering workforce productivity – one value is provided for each engineering location, relative to the engineering productivity at the country base location • Engineering Indirect Costs – values are provided for each location for each of the eight phases of engineering: o Expense rates o Payroll burdens o Office indirects The eight phases of engineering are: o Basic Engineering o Detail Engineering 9 Changing Plant Capacity and Location 308 • o Procurement o Engineering Management o Home Office Construction Services o Field Office Supervision o Construction Management o Start-up, Commissioning Engineering confidence level, associated with the sources of the ARM knowledge base data, used to compute a value of engineering contingency. Engineering contingency is computed as the root-mean square value of the user engineering contingency and engineering confidence level. For example, if the user contingency before relocation UC =18% and the ARM location confidence value LC = 10%, then the computed contingency after relocation is: = √ (UC2 + LC2) = √ (182+102 ) P P P P P P P = 20.6% P Construction The ARM knowledge base contains a comprehensive set of construction workforce values, which should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site. The following are provided by ARM for each construction work force location: • Field Craft rates – hourly rates (“nearly all-in”) for each of 28 field crafts in the construction work force slate and a foreman differential for each location. By “nearly all-in”, we mean that each craft rate is a unique composite of the following rate contributions: o Craft Worker Base Hourly Wage Rate o Health, Welfare, Pension o Fringe Benefits o Hourly Indirect Rate for: Temporary Construction Consumables and Small Tools FICA Unemployment Workers Compensation Insurance Multi-level construction Craft rates in the ARM knowledge base do not include indirect construction costs for the following categories as these would be determined during project evaluation: • o Construction Equipment Rental, including Fuel, Oil, Lubrication, Maintenance (FOLM) o Field Supervision o Contractor Home Office Costs Construction workforce productivity – one value is provided for each plant location, relative to the construction productivity at the country base location 9 Changing Plant Capacity and Location 309 • Field indirect costs, including construction equipment rental (see Project Data, below), field supervision, home office costs • Work week: hours, number of shifts, overtime • Construction equipment rental: slate of items (see Project Data, below) • Extent of hand excavation vs. machine excavation • Construction confidence level, associated with the sources of the ARM knowledge base data, used to compute a value of construction contingency. Contingency is computed as the root-mean square value of the user construction contingency and construction confidence level. For example, if the user contingency before relocation UC =18% and the ARM location confidence value LC = 10%, then the computed contingency after relocation is: = √ (UC2 + LC2) = √ (182+102 ) P P P P P P = 20.6% P P Material Costs • Location Indexing The ARM knowledge base contains a set of location indexes which will adjust country base material costs to the plant location. Two sets are provided: o The first deals with equipment costs. o The second applies to bulk materials. Use of the supplied location indexes should be considered as a starting point in the evaluation of a project. Concerned users should replace the ARM knowledge base values in their relocated project with more representative values obtained from company surveys of the intended site. The location indexes make use of Aspen Richardson values for the average split of local vs. imported materials. Costs of local and imported materials are figured by applying location values for freight, taxes, VAT, and other expenses. Location indexes are stored for each of the four-country bases and are used to characterize material costs by account code (100 to 299 for equipment, 300 to 999 for bulk materials.) o Unit cost of rebar, ready-mix concrete, in the currency of the plant location o Material cost confidence level, associated with the sources of the ARM knowledge base data, used to compute a value of material cost contingency. Contingency is computed as the root-mean square value of the user material contingency and material cost confidence level. For example, if the user contingency before relocation UC =18% and the ARM location confidence value LC = 10%, then the computed contingency after relocation is = √ (UC2 + LC2) = √ (182+102 ) P 9 Changing Plant Capacity and Location P P P P P P = 20.6% P 310 10 Analyzer Utility Modules Introduction Analyzer Utility Modules (AUM) – Design and Scope Generators for Utility Systems One of the difficulties with process economic analyses, both capital cost and payback determination, is the lack of scope definition for non-process or outside boundary limit (OSBL) portions of the project. With AUM modules creating utility systems in harmony with the process sections of a project, more accurate, realistic and confident business assessments can be made for cost and economics. Each AUM module works in the same way. It extracts information on the specific utility needs of each project component and area in your project. You can then interactively revise default values for design preferences and configuration, evaluate messages, review reports of design results. On completion, a press of a Load button will automatically transfer to your project, a list of selected, sized, designed project components assembled within a unique date- and time-stamped utility area. Should a prior utility area of the same type be present in your project, you can chose to delete the old one and replace it with new scope. All of this takes place in times measured in minutes rather than traditional days and weeks. Of course, evaluation time depends on the size of the project. For front end engineering design work, AUM modules can be revisited in each cycle of scope change to ensure the project needs are properly satisfied by each utility system. A Control Panel, a task bar button and numerous hypertext links provide for easy navigation and rapid access to a status report, specs for preferences and configurations, reports, an a guide. Messages are provided to assure data integrity; an error condition will disallow loading of results into your project. 10 Analyzer Utility Modules 311 AUM_CW: Cooling Water Utility Selection, Sizing, and Design Module The cooling water utility module requires Aspen Process Economic Analyzer or Aspen Process Economic Analyzer plus Aspen Process Economic Analyzer to identify cooling water resource streams and their flow conditions. Up to four cooling water systems can be configured for a project, each with its own set of sized components: cooling towers, circulation pumps, chemical injection pumps, supply and return distribution piping, valves, and fittings. You can interactively define design conditions such as ambient air temperatures, size limits to distribution piping, equipment types, and assign individual areas to each cooling water system. Redundancy capabilities include stand-alone pumps, two 50% capacity pumps, stand-by spares. Distribution piping includes expansion loops for long runs and circuits include main lines, branch lines, area headers, and risers and laterals for 3D-type areas. Each line type has its own “iso” for valve and fitting type. Line sizes and pump heads are pressure drop based. AUM_Air: Instrument and Plant Air Utility Selection, Sizing, and Design Module The air utility module can be accessed by either Aspen Process Economic Analyzer or Aspen Process Economic Analyzer. AUM_ Air gathers air requirements from your project in two ways: • Instrument air: From a count of air operated control valves and controllers and instrument air flow required for each based on control valve size • Plant air: From an air usage model based on a common air tool usage set, with area utility stations derived from area size and equipment count within an area Up to four air plant units (APU) can be configured for a project, each with its own set of sized components: • air intake filters/screens • ductwork • compressors • interstage coolers • air receivers • pre-filters • air dryers • after-filters • piping distribution network You can interactively define design premises such as ambient air conditions, equipment types, equipment redundancy, etc. and assign individual areas to be served by each air plant unit. Redundancy capabilities include stand-alone compressors, start-up compressors, receivers, dryers. Redundancy choices include one at 100% capacity, two at 50% capacity, stand-by spares. Distribution piping includes two sets, each sized for the required flow of instrument air and plant air. Piping isos for line segments include expansion 10 Analyzer Utility Modules 312 loops for long runs, valves and fittings, Line segments are defined for main feeders, main manifolds, main lines branch lines, area feeders, area headers and for 3D–type areas, risers and laterals. Each line type has its own “iso” for valve and fitting type. Line sizes are pressure drop based. Analyzer Utility Module (AUM) Cooling Water (AUM_Water) Introduction to Analyzer Utility Module (AUM) Cooling Water Cooling Water Selection, Sizing, Design Model This section is divided into four parts: 1 Overview • Analyzer Utility Module (AUM) • Cooling Water Design Model o Value in Time and Effort o The Key Steps 2 Working with the Cooling Water Model • Preparation Workflow • The Workflow Cycle • Accessing The Cooling Water Model • o Interactive Session Workflow – the Design Phase o Overview o Details of the Work Process o The Initial Design Interactive Session Workflow – The Design Phase o Overview o Details of the Work Process o The Initial Design 3 Working with the Cooling Water Model Worksheets • Introduction o Worksheets o Button actions • Cooling Water Design Model Worksheets • Worksheet Details o Status Worksheet o Preferences Worksheet 10 Analyzer Utility Modules How to Revise Default Values 313 o Design Preference Categories Circuits Worksheet Initial Configuration Step 1: Assignment of Areas to Circuits How Area Assignments are Used for Circuit Design Step 2: Assignment of Spacing Between Areas Status messages and Values Used for Circuit Design 4 Basis for the Cooling Water Design Model o General Flow sheet for cooling water service o Cooling Water Model Circuitry o Cooling water distribution network o Naming conventions Project cooling water area Areas Requiring Cooling Water Plant bulk pipe item descriptions Distribution Piping Line types o Sequencing of Areas on the Main Line o Cooling Water ”Footprint Model” o Pipe, Valves and Fittings Count o Line Sizing and Pressure Drop Calculations Projects with a prior cooling water utility model area Cooling towers- terminology and the defining stream temperatures 1. Overview Analyzer Utility Module (AUM) Water One of the difficulties with economic analysis, both capital cost and payback determination, is the lack of scope definition for non-process utility or outside boundary limit portions of the project. The Analyzer Utility Module, AUM, was created as the “home” for a series of automated utility design models to address this difficulty. The Cooling Water Selection, Design and Sizing Model is the first utility design model in AUM and its functionality and method of use is described in detail in this chapter. Cooling Water Design Model The Cooling Water Design Model is an automated, interactive and rapid design module that is contained in Aspen Decision Analyzer and works with streambased projects. The cooling water model identifies heat exchanger equipment or any other type of project component that requires cooling water by its connection to a cooling water utility resource stream. 10 Analyzer Utility Modules 314 To access the Cooling Water Design Model: 1 Starting with an open project that contains utility streams as part of its definition, click Run, then click Utility Model. Or, simply click the U button to access utility models. 2 Click Cooling Water. At this point built-in design and processing procedures do all the hard work under your control and guidance and a few minutes later, your project will be augmented with a new cooling water utility area that contains designed cooling water circuitry and associated project components. You can use the model results using its set of adjustable design parameters or revise any and default values within prescribed limits to suit your needs. In the discussions to follow, the term early design metrics is used to indicate values prepared by the cooling water model during an interactive design session. These are presented for guidance in advance of final design values that would be prepared on completing a project evaluation run. Note: Worksheet names are shown in italic bold face to distinguish the names from text. Value in Time and Effort The cooling water design model does all the hard work – design, selection, reporting, loading the design results – in minutes rather than traditional hours and days. It is a powerful resource in the development of a typical Front End Engineering Design: • Early process technology evaluation stage - focus is on Inside Battery Limits (ISBL) components • With the process technology selected and additional scope, total project costs are sought. Outside Battery Limits (OSBL) components are required, particularly cooling water utility service. The cooling water design model • Automatically selects, designs, and adds sized utility system components to the project scope definition • Can be revisited in each cycle of scope change. The Key Steps On initiating the cooling water model, the model automatically analyzes your project for cooling water requirements and automatically generates selected, sized and designed cooling water utility service project components – all based on initial default design preferences and circuitry. Two interactive workbooks Preferences and Circuitry enable you to revise default values for the design and selection basis. Studying design alternatives starts with either a click of an option box or a data entry. Being interactive, the cooling water model enables you to cycle from design basis to early design results in a matter of mouse clicks. Each new specification results in a new design and a report of key decision metrics. The list of sized project components is retained until you choose to load the results into your project. Messages and 10 Analyzer Utility Modules 315 metrics reports are provided extensively to guide you quickly and knowingly through a study of design alternatives. When you have settled on a design you can load the results into your project. The loading operation begins with a click of a Load button and processing is automatic. After a minute or so, the loading process will be complete and the Project Basis view will be displayed on your screen. Scope items added to your project include a uniquely named cooling water area followed by a list of cooling water utility project components: cooling towers, circulation pumps, chemical injection pumps, working and stand-by spares, and distribution piping, valves and fittings. Each component is selected, designed and sized in harmony with your design basis and the needs of heat exchange equipment in your various project areas. 2. Working with the Cooling Water Model Preparation Workflow The Cooling Water Design model requires a stream-based project built in either Aspen Process Economic Analyzer or Aspen Decision Analyzer, with components that require cooling water connected to one or more cooling water utility resources. The flow rates, water temperatures, duties and components provide the basis for the design requirements. The cooling water model will first diagnose the project’s requirements and initiate a design. The user can then revise the design basis and review early design metrics for a variety of design scenarios, settle on a design basis and load the design results into the project. The Workflow Cycle Figure 2.1 illustrates the cooling water design cycle: from project to design model and back to the project with added new scope. Two buttons control the process: • U to select the cooling water model • Load to load designed results Using these two actions, you can participate interactively in the design process, making design selections, reviewing early metrics, revising selections, and clearing any error messages. 10 Analyzer Utility Modules 316 Figure 2.1. The Workflow Cycle, extracted from the Welcome worksheet To initiate a cooling water design model session, three steps are required 1 Save the project under a new scenario name. 2 Evaluate the project 3 Run the Cooling water utility model Each of these steps is detailed and illustrated in the following sections. Accessing the Cooling Water Utility Model 1 SAVE AS: Since AUM-Cooling Water processing is automatic, it is wise to first save your base project under a new name. This will ensure that your base project remains intact for further evaluations. 10 Analyzer Utility Modules 317 2 Evaluate the project: Click Run |Decision Analyzer as in Figure 2.2a or click the A button as in Figure 2.2b. This will provide the Decision Analyzer dialog box, Figure 2.2c. Check Evaluate Project and provide a file name. Figure 2.2a. To evaluate from Run: Figure 2.2b. To evaluate using the A-button. Figure 2.2c. Choose Evaluate Project. The reason for this step is to ensure that the project scope and cooling water requirements developed during evaluation are current and up to date. It will also eliminate an error message (Figure 2.2d) that would be displayed when accessing the cooling water model no evaluation data were available. . Figure 2.2d. Error message if the project was not evaluated 10 Analyzer Utility Modules 318 3 Select the Cooling Water Model: To do this, choose Run>Utility Model (Figure 2,2a) or press the “U” button on the button bar (Figure 2.3a): Figure 2.3a. To obtain utility models using the U-button. This will bring up the Utility Model dialog box, Figure 2.3b. A blank value under Status indicates the project does not contain a prior cooling water model area. If a project contained a prior area, the Status field would indicate Loaded. Figure 2.3b. Utility model selection 3b Select Cooling Water: Click OK. This will either initiate an interactive Cooling Water Design session in MS Excel and display a Load option or display a project-not-evaluated error message (see Step 2 above). Interactive Session Workflow – the Design Phase Overview When the cooling water model is invoked, it: (a) analyzes for project cooling water requirements (b) works from Preferences (user-modifiable, default set of design parameter values) (c) prepares an initial design. Results of the initial design and any subsequent interactive scenario are presented in a Capture worksheet. If the design meets with the user’s approval, a user click of the parked Load button will load the design results into the project, at which time the project can be re-evaluated. The Preferences and Circuits worksheets allow the user to modify the default design basis. Each spec change will result in a new design. Hyperlinks provide rapid access from one sheet to another and sections in a sheet. The 10 Analyzer Utility Modules 319 Control Center toolbar button opens the Control Center worksheet, which has hyperlinks to other sheets and their major categories. Worksheet tabs are color coded to match hyperlinks at the top of each worksheet. The following sections provide a detailed description of the work process as well as detailed descriptions of each worksheet, category and item. Details of the Work Process With the click of the OK button in step 3b above, three actions will occur 1 The model first identifies if a prior cooling water model area is present in the project. If present, the user can choose to Delete the prior area and continue with the model or return to the project. If Delete is chosen, the utility model will proceed with the design and delay deletion until it is time to load the new results. 2 If no prior cooling water utility area is detected, the Welcome screen is displayed and remains present during a time when: a Project requirements are automatically passed to the model b The model prepares an initial design c A Load | Cancel | Minimize option is provided (Figure 2.4). To at the top. This will park the continue, click the minimize button button box for access during the design phase. Cancel will end the cooling water model session and return normal project functions with no change to the project. Figure 2.4. Load-Cancel-Minimize button boxes 3 • a Control Center button bar (figure 2.5) is provided to access the Control Center worksheet from any worksheet • Seven worksheets are presented in a MS Excel framework: o Welcome o Control Center o Status o Preferences o Capture o Guide The model then displays the Control Center worksheet, which links to all other worksheets and provides an indication of success (green signal) or failure (red signal) to create an initial design based on default design parameters. 10 Analyzer Utility Modules 320 The Initial Design On initiation, the cooling water model will report the Status of the design on the Control Center (see Figure 2.5) worksheet under Status Report, and if any, will identify clashes on the Status worksheet and further, on the Preferences and Circuits worksheet. A Status Report message: “Successful. A Load can proceed” indicates all is well between project requirements, design parameters and design methodology. At this point, it is wise to review early design metrics by accessing the Captured Results worksheet (see Figure 2.6). The user can return to Preferences and Circuits to study design alternatives. If captured results are acceptable, a click of the parked Load button will (1) carry the design results into the project, (2) close the worksheets and (3) return to the project for evaluation of the augmented project. Should the design basis produce a clash with project requirements, error messages and flags will be displayed in a top-down succession of worksheets. The first indication is given under Status Report on the Control Center Worksheet. The Status worksheet is the central reporting agency, where checks are made and links are provided to source locations in the Preferences and Circuits input worksheets. Figure 2.5. Illustration of the Control Center Worksheet, with display of Control Center toolbar and Load button 10 Analyzer Utility Modules 321 Figure 2.6. A section of a Results Capture sheet showing values in the project units of measure set. 3. Working with the Cooling Water Model Worksheets Introduction Worksheets: Seven worksheets are provided, of which Preferences and Circuits are for user input, to revise the design basis: • Welcome: greetings, workflow graphic • ControlCenter: navigation • Status: message center • Preferences: design selections • Circuits: circuit definition • Capture: early design metrics • Guide: help Button Actions: The Control Center toolbar is always available during a model session. A click will open the Control Center worksheet and a hyperlink click will direct you to a chosen worksheet. When the Control Center toolbar is parked together with the Excel Web toolbar you can quickly search forward and backward. 10 Analyzer Utility Modules 322 You can step from one sheet to another, revise the design basis, review status and results, decide on an alternate design basis, make revisions, review the results and when ready, click the Load button (see Load-CancelMinimize) to inject the results in the project. Or, you can refuse the design using Cancel. Clicking Load conveys the design results to the project, the cooling water design model’s Excel sheets and return to normal Analyzer functions. Cancel bypasses the cooling water model and returns to Analyzer. Cooling Water Design Model Worksheets The SPECS cooling Model workbook consists of • Two design basis sheets – this is where you input your selections o o Preferences: process and mechanical design specs: Red error flags and messages are displayed for out of range or missing data values Uses click boxes for either/or choices, “B” and “R” switches to select base (default) or revised value and user value to replace the base value Circuits: assignment of areas to a circuit, spacing of areas in a circuit along the main line: Assignment uses 1, 2, 3, 4 to assign an area to a circuit Spacing uses the “B” and “R” switch method and user spacing to replace the base footprint model value 2H • Status sheet – all messages are summarized here for your review and repair o Key status message is highlighted in color (green: Loading can be performed, red: Errors must be cleared) o Summarizes other messages, links directly to input locations for revision • Capture Results: displays early design metrics for decision making, provides the basis for alternative choices of preferences or circuitry. By “early design metrics” is meant values in advance of those created during project evaluation • Guide: provides instructions, describes data entry, color coding • Control Center: hypertext links interconnect all sheets and main categories for rapid navigation • All sheets: are conveniently color coded, with red flags appearing on error condition. All error conditions must be cleared before results can be loaded • Welcome sheet: Welcome, displayed during the initiation process, contains a workflow graphic On completion of an error-free interactive session, pressing the LOAD button will automatically load and inject the results into the project. The project will then contain new scope additions: (1) a uniquely named, time-stamped cooling water area will be used to contain (2) a selected, designed list of cooling water utility project components. Each item so added by the model may be opened, reviewed, revised in the same way as any other project component. 10 Analyzer Utility Modules 323 Worksheet Details Status Worksheet The Status sheet reports messages and has hypertext links to source locations in the event of a reported error. Major report categories are: • Overall status • Existing cooling water area is in the project • Cooling circuit components – wet bulb temperature, minimum approach temperature, lowest desired cooling water temperature • Cooling water resources: naming, excluded streams and reasons, net number • Project components: total, number served by cooling water • Project areas: total number, those served by cooling water • Cooling water loads: total flow rate, total heat duty, excess capacity, total flow rate at excess capacity • Layout distances: number of parameters out of range • Pumps specs out of range • Piping specs out of range • Circuit assignments out of range • Spacing assignments out of range Figure 3.1 illustrates an extract of a Status sheet Figure 3.1 Extract, sample of a Status Sheet Preferences Worksheet Units of measure used in the Preferences worksheet correspond to those defined in the project. Error messages are displayed alongside each entry; errors are flagged in red. This sheet uses click boxes and data entry fields for 10 Analyzer Utility Modules 324 specifying design preferences. Each preference is provided with a explanatory text, limit values, user entry field and a default value which is used in the initial design and any subsequent design should the user not provide an over-ride selection or value. How to Revise Default Values This worksheet uses two methods, check boxes and data entries controlled by switch boxes to revise the supplied set of default (base) design parameters. Throughout data entry discussions, the term used for a model-supplied set of data is referred to as default values. For a particular parameter, the modelsupplied value is termed a base value, symbolized by the letter B. A value supplied by the user is termed a revised value and is symbolized by the letter R. A mouse click will switch between using a base value and a revised value. See Figure 2.2c (page 318) for information on how to use a check box: 497H • A default value is provided to the left of the check box • A check box title signifies the alternative to the default value • The resulting choice is displayed to the right • A status message is displayed that provides additional information Figure 3.2 Extract, sample of a Preferences sheet showing click box method of selection Design Preference Categories: • Cooling Tower (values in this section affect the circuitry, sizing of cooling towers and flow-related equipment such as circulation pumps and distribution piping) (a) Design Capacity, excess capacity (b) Design Temperature: Summer wet bulb temperature (see Cooling Tower discussion of wet bulb temperature, approach gradient, range) 3H (c) Messages relating to cooling water resource requirements vs. design preferences (d) Number of Cooling Towers 10 Analyzer Utility Modules 325 (e) Multiple Cooling Towers: choose either one tower for all circuits or one for each circuit (f) Working “Twin”: choose a single tower at 100% capacity or two “(twins), each at 50% capacity • Layout (these are dimension limit checks that are applied to entries on the Circuits worksheet o • • Distance From tower to first branch to an area Minimum value to first branch to an area (often defined by fire regulations) From a branch to an area header Maximum spacing between areas (a limit check) Status messages related to distance Pumps o Area Pressure Drop: pressure drop for equipment requiring cooling water, applies to all areas o Working Pumps Limiting value for number of working pumps in a circuit Pump type: horizontal (CENTRIF or API 610 model types) or vertical (TURBINE model type, at low speed only) Pump speed: low or high RPM Stand-by pumps if four or less pumps in a circuit: yes or no Stand-by pumps if more than four pumps in a circuit: yes or no Electrical power to pumps based on voltage choice: LV (low-voltage), MV (mid-voltage), HV (high-voltage). Limiting values of power per pump motor are displayed based on project specifications. A voltage choice defines the maximum power to a motor driver and hence, the number of pumps in a circuit. Recall that each change to a specification results in a completely new design; a voltage selection results in a design value for the number of pumps and can produce an error condition and message if the number of pumps exceeds the limiting value for number of pumps in a circuit. Design messages for pumps and piping for each of four possible circuits Piping: Limiting values for line size, by line type, where line sizes are in the units of measure of the project, either “IN DIAM” or “MM DIAM” 10 Analyzer Utility Modules Suction line size for circulation pumps (a flow rate per pump suction line based on selected line size is provided for information purposes) Main line segment line size Branch line size Area header line size 326 Risers line size (for 3D area types) Laterals line size (for 3D area types) Circuits Worksheet Units of measure used in the Circuits worksheet correspond to those defined in the project This worksheet is designed to handle up to one hundred cooling water areas. Areas are listed vertically. The worksheet is divided into five major categories in columns of data: 1 Initial Configuration See Figure 3.3 for the initial configuration Figure 3.3 Extract from Circuits sheet – Initial Configuration (left), Step 1 (right) The following (see Figure 3.3, left side) are reported for each area being served by a recognized cooling water utility resource stream: 2 • Initial Sort Sequence: sequenced by area, from the area with highest cooling water requirements to the area with the lowest • Area Name: user-assigned name, carried into the cooling water design model from project area specs • Area Type: user-assigned area type, carried into the cooling water design model from project area specs • Area CW Rate: area cooling water (CW) flow rate, the sum of all recognized cooling water flow rates for equipment in an area as adjusted by the Excess Capacity value in the Preferences worksheet • Initial Circuit Number: always 1 as all areas are initially assigned to a single circuit • Initial Circuit ID: always “A” Step 1 – Assignment of Areas to Circuits (User entry one of two) Please refer to Figure 3.3 (right side): 10 Analyzer Utility Modules 327 3 • Enter a Circuit Number 1, 2, 3, or 4: user value is required; if only one area requires cooling water, enter 1. If two areas, use 1 for both or assign 1 to one area and 2 to the other. The design model will sequence the areas. In an error condition, an error message and a red flag will be displayed. Error conditions must be resolved to obtain loadable design results. • System-Assigned Circuit Id: The model will assign a letter ID (A, B, C, D) to each area based on circuit assignments and total circuit flow rate. If the project contains four or more areas, then it is possible to assign areas to circuit numbers 1 to 4. The model will collect all the area flow rates in each circuit and sequence the circuits from greatest flow to least in the sequence A, B, C, D. The “A” circuit will have a larger total flow rate than circuit “B”, “B” will be greater than circuit “C” and “D” will have the least flow rate. Similarly, for three areas in a project, valid circuit numbers range from 1 to 3 and circuit IDs assign to these circuits, based on total flows will be sequenced and labeled A, B and C. A one-area project will be assigned a circuit ID of “A.” • Status o Status of all entries: summarizes number or errors to be resolved; if none, “OK” is displayed o Status for individual entries: message is issued for invalid circuit numbers and field is flagged in red How Area Assignments are Used for Circuit Design Please refer to Figure 3.4 Figure 3.4 Extract of Circuits sheet – defining area spacing using the B/R switch Each line item in this section represents an area and its properties. Areas are sorted and sequenced in descending total circuit flow rate and then by area flow rate. Circuits are labeled A, B, C, D with circuit A being the one with the highest flow rate; B is next etc. An area that was tagged as circuit 2 in step 1 may be in a circuit with the lowest flow and would be organized accordingly and given a Circuit ID letter depending on the other circuit flows. This section displays the properties and attributes of each area in the sequenced list. 10 Analyzer Utility Modules 328 Values displayed for information purposes are: • New Sort Sequence: displays values vertically in the sequence 1, 2, 3, etc • • Initial Sort Sequence: displays the initial sort sequence number for the area ID of Area In Report Group (ArRg): the ArRg ID for the area • Area name: user-assigned project area description 4H 5H Area CW Rate: displays the cooling water rate, as adjusted by the Preferences value for excess capacity • 6H • Area Heat Duty: heat duty requirements for all equipment within the area identified as requiring a valid cooling water resource • • • User circuit number: value entered in Step 1, for reference purposes Circuit ID: letter A, B, C, D assigned by the cooling water model based on sequencing circuit flow rates 7H Position Of Area In Circuit: Only one area can be first in line in a circuit. “First” if the area has the highest flow rate of all areas in the circuit, otherwise no a blank display. The area with a “First” position will take on a default distance from the cooling tower as defined by the Preferences value for that distance. 4 Step 2: Assignment of Spacing Between areas Each line item in this section corresponds to item 4 above. A line item represents an area and its properties, with areas being sorted and sequenced in descending circuit and area flow rate. This section enables the user to revise base values for the spacing of areas along the main line. It uses the “Switch” method to revise a base value as described in the section on Preferences. • Base Value for Spacing Along Circuit Main Line: This is the run length of the main segment between the prior and current area as developed by the footprint model. 8H • • Enter Switch: B for Base, R to revise. Choose a blank entry or enter either a B (or b) to indicate use of the base value. Use R (or r) to indicate use of a revised value o Switch value is blank: design will use the base value o Switch value is B or b: design will use the base value o Switch value is R or r: indicates a forthcoming user value will revise the default spacing value. The design will use the revised value if the user value is within range of prescribed limits. Enter Revised Spacing Along The Circuit Main Line: This value will replace the base value if it meets range limit conditions set forth in the Preferences worksheet. By spacing is meant the distance between successive areas. As the line items in this section represent areas that are sorted and sequenced, the spacing for a particular line item is the spacing between the start of the prior area and the start of the current area. This spacing is a measure of the area’s main line segment. See the section on the Cooling Water Footprint Model. Piping runs lengths are typically longer than spacing as they include pipe to configure fittings, expansion loops, etc. 9H 10 Analyzer Utility Modules 329 Enter a value. The resulting action depends on the corresponding switch value o Switch value is blank, B or b: user value is ignored, base value will be used o Switch value is R or r: user value is tested against range limits and design criteria. If error free, the user value will be displayed as the Applied Value. Error conditions will display instructional status messages, red flag, and prevent completion of a valid design 5. Status messages and values used for design o Flag: A red flag is displayed to indicate a line item error condition o Status: B (Base) uses base value, R (Revise) uses revised value or status message (displays limiting values, error messages) o Value used for spacing along circuit main line: The value used in the design 4. Basis for the Cooling Water Design Model This section describes the basis of the cooling water design model. It is presented with numerous graphics to enable a clear understanding of the work being performed by the model when it is analyzing and designing cooling water project components that are in harmony with your design preferences and the needs of components requiring cooling water. General Flow Sheet for Cooling Water Service Figure 4.1 is a schematic diagram of a typical cooling water circuit. In this figure, circulation pumps draw cooled cooling water, the cooling water supply stream, from the supply basin at the bottom of a cooling tower and distribute it through piping to heat exchanger located in one or more project areas. Cooling water return streams are combined and sent to a cooling tower where it is cooled, principally by evaporative cooling. Motor driven fans mounted on the tower draw (induced draft) or force (forced draft) ambient air into the cooling tower where it contacts the downward flow of cooling water. The cooled cooling water drops down from the tower into a supply basin, awaiting withdrawal by the circulation pumps. Water is added to make up for losses through evaporation, air-born drift and for blow-down. Water drawn from the system to prevent the build-up of contaminants is termed “blow-down.” See below for more on cooling towers, terminology and defining stream temperatures 10H Cooling water in such a circuit tends to accumulates algae, corrosion contaminants and particles that slough off the distribution system. Water treatment chemicals are added to alleviate these conditions, with the degree of such treatment depending on the water supply source and environmental conditions. Five types of treatment chemicals are typically used in small 10 Analyzer Utility Modules 330 quantities to control the water quality. The cooling water model provides each cooling tower with a diaphragm type of pump and a stand-by for each of the treatment chemicals. The model uses the following labels to identify the types: • Sulfuric acid (pH control) • Sodium hypochlorite (pH control) • Biocide (algae growth control) • Corrosion inhibitor • Dispersant (suspended particles control) Figure 4.1 Illustration: Cooling Water Flow Diagram Cooling Water Model Circuitry The cooling water model is designed to support up to four independent cooling water circuits. Each circuit can have its own cooling tower or all circuits can be defined to share a cooling tower. A circuit consists of pumps and distribution piping to and from project areas. It is the P&ID specs that define the component’s hook-up piping to the cooling water model’s circuitry. Summarizing, the cooling water model develops piping runs to a project area and distributes cooling water to components in the area via an area header or risers and laterals in the case of 3D area types. Each circuit is provided with a supply and return distribution network; what is supplied must be returned: one supply line implies one return line. Figure 4.2 is a schematic diagram showing several areas that have equipment requiring cooling water and one that does not. The cooling water model will not serve an area that does not have cooling water requirements. If such an area is to be included, then it is recommended that one or more exchangers connected with cooling water utility streams be introduced in that area. The cooling water model allows for a one cooling tower (or two 50% towers) to serve all circuits or individual cooling tower (or two 50% towers) for each circuit. Clearly, if only one area requires cooling water, only one circuit can be defined, up to two circuits for two areas, up to three circuits for three 10 Analyzer Utility Modules 331 areas and a maximum of four circuits for four or more areas requiring cooling water. Figure 4.2 Single, Independent Cooling Water Circuit Figure 4.3, case (a) is a diagram showing a single treed circuit. Figure 4.4, case (b), illustrates multiple treed circuits. The difference between the two cases is (a) one cooling tower for each circuit or (b) one for all circuits. Case (a) would apply to projects with a single area or for multiple circuits, with each circuit being served by its own cooling tower. 10 Analyzer Utility Modules 332 Figure 4.3 (case a). Illustration of one cooling tower used to serve a set of areas in a single circuit. The model will permit up to four single circuits, each having its own cooling tower and circulation pumps. Figure 4.4 (case b). Illustration of one cooling tower used to serve multiple circuits. For this case, the model will provide one cooling tower for all circuits and a set of circulation pumps for each circuit. 10 Analyzer Utility Modules 333 Cooling Water Distribution Network This section describes the methodology used in circuit design • Naming conventions • Sequencing of areas on the main line • Cooling water footprint model • Pipe, valves and fittings count • Line sizing and pressure drop calculations Naming Conventions Project Cooling Water Utility Area: The cooling water design model will create a cooling water model utility area to contain project components for each circuit. On loading, the area will be named with a date and time stamp to ensure it is unique and can be detected and properly deleted when a new design is to take its place. The naming convention is: “AUMCoolWater ddmmmyy_tttt”, where • dd is the day number of the session month (1, 2, 3, ….., 31) • mmm is a three character representation of the session month (jan, feb, mar, apr, may, jun, jul, aug, sep, oct, nov, dec) • yy is the last two digits of the session year (05 for 2005, etc) • tttt is the decimal fraction of the session day Utility project components are time-stamped in a similar manner. As only four digits are used (tttt), it is possible that a load action might span two tttt times (one ten-thousandth of a day, duration of 8.64 seconds) with no significant resulting consequence. Once a cooling water utility area is loaded in the project, the user may access any item in the usual way, by using the Project View, clicking on any component and viewing the design parameters in the forms view. Any and all data in the cooling water utility area may be modified as required. Areas Requiring Cooling Water: Each area that requires cooling water is identified by a unique ArRg number that is made up of system–assigned numeric values for Area ID and Report Group. An ArRg value of 201 indicates Area ID = 2 in Report Group 1. The user-assigned area description, which may not be unique in a given project, is printed in reports along with its unique ArRg value. Plant Bulk Pipe Item Descriptions: The naming convention above is combined with the Area Code and is time stamped when loaded into the project. For example, “MainSeg, ArRg 201_T7883” is the item description for main line supply and return line segment that serves area 2 in report group 1, time stamped T7883. Distribution Piping Line Types: The distribution network in this cooling water model consists of the following named types of lines: • Main line segment: a portion piping along the main line 10 Analyzer Utility Modules o “MS” o “MainSeg” o “MainChk” for a main segment that contains a check valve 334 • • • • • Branch segment: a short run of pipe, from the main line to a specific project area o “B” o “Branch” o “BrChk” for a branch that contains a check valve Area header: a line of pipe, valves and fittings that distributes cooling water along the long dimension of the base of a project area o “AH” o “Area Header” o “ArHdrChk” for an area header that contains a check valve Risers – vertical runs of pipe to bring cooling water to each level in a 3d structure o “R” o “Risers” o “RiseChk” for a riser that contains a check valve Laterals – horizontal runs of pipe that distribute cooling water to each floor in a 3D structure o “L” o “Laterals” o “LatChk” for a lateral that contains a check valve Vents and drains – high-point vents, low-point drains on supply and return lines, short runs of small bore pipe o “VD” o “VentDrain” Lines with check valves are of minimal length to satisfy the plant bulk PIPE mode and are separate line items as only one check valve is assigned to a supply-return line pair. Figures 4.5 and 4.6 illustrate these line types for 2D (PAD, GRADE) and 3D area types (OPEN, EXOPEN, FLOOR, MODULE) 10 Analyzer Utility Modules 335 Figure 4.5 Schematic of cooling water piping for a 2D area type (PAD, GRADE) Figure 4.6 Schematic of cooling water piping for a 3D area type (OPEN, EXOPEN, FLOOR, MODULE) 10 Analyzer Utility Modules 336 Sequencing of Areas on the Main Line Upon identifying which areas that require cooling water and their assigned circuit, the cooling water model arranges the areas in decreasing cooling water usage. The largest consuming area is placed at the front of the line and the smallest consumer is placed at the end. In this way, min line segments will be larger in diameter at the front of the line and decrease as each consumer reduces the total flow rate to the next area. Figure 4.7 illustrates various line types and sequenced areas. Figure 4.7 Schematic of Line Types Serving Areas Requiring Cooling Water Cooling Water “Footprint Model” Upon identifying an area as one that requires cooling water, the footprint model develops an area footprint by using (a) the total number of components in an area, (b) the area type (2D or 3D), (c) the number of level and (d) a packing density (number of components in a bay) and (e) area aspect ratio, length:width, of 1.5:1.0. The result of the footprint model is a set of dimensions for each area requiring cooling water. These dimensions are used to develop a default value of the spacing between the start of one area along the main line and the next area. The default spacing distances are reported in the Step 2 of the CIRCUITS worksheet and can be over-ridden by the user. Pipe, Valves and Fittings Count Each line type is provided with a piping iso model that consists of set of pipe, valves and fittings. Pipe and fitting diameter is determined by volumetric flow 10 Analyzer Utility Modules 337 rate and limiting line velocity (suction lines being different from distribution lines). Line length is determined by (a) minimum length of pipe required to each type of fitting and (b) the long area dimension, which is developed from a cooling-water “footprint model” for each project area and area type. Fittings are assigned to each line type from a list that includes elbows (EL), tees (TE), reducers (RE), flanges (FL), blind flanges (BL), gate valves (GA), check valves (CH). 1H Each line type is based on five configuration components. The total line length is determined by as the sum of the linear run distance plus pipe lengths of pipe to satisfy the make-up of the configuration components. The make-up of each configuration component is based on line type and consists of quantities of the following: • “Main run” component: pipe, of length determined by (a) the footprint model, or (b) user preference value • “Fixed” component: FL, GA, CH fittings, pipe length based on diameter of run • “Head” component: EL, FL fittings, pipe length based on diameter of run, to provide directional change • “Branch point” component: TE, RE, FL, BL fittings, for connection to next line type • “Vent and drain station” component: TE, FL GA fittings, pipe; frequency of placement is based on linear run distance • “Expansion loop” component: EL fittings, pipe length based on diameter of run, frequency of placement is based on linear run distance Expansion loops and vent and drain stations are placed along the run based on line length The configuration of each line type serving each area is defined as a project component located in the cooling water area created by the cooling water model. Once loaded in the project, any line configuration can be reviewed and modified in the usual manner by opening that project component in its form. Line Sizing and Pressure Drop Calculations The Cooling Water Model has a Preferences worksheet where, in the Piping section, limiting sizes of each line type are defined. Once areas are assigned to a circuit, the flows through the circuit are known. Areas are ordered in sequence according to their flow requirements, with the largest consumer at the head of the line. The computations are interactive and a new design will be computed unnoticed each time a design value is revised. It is wise to check early design results that are displayed in the Capture worksheet when revising design specifications. Line size and pressure drop computations take place in this general manner: • Starting point is limiting velocity, as defined in the Icarus Reference Guide • Flow rate combined with limiting velocity results in required flow area • Maximum line size determines number of parallel lines 10 Analyzer Utility Modules 338 • Built-in iso for each line type defines valve and fitting count • Line length is derived from spacing between areas from circuitry input, minimum spacing between areas and minimum lengths from line • Total run length is a combination of line length and number of parallel runs • Pipe friction is based on Fanning type equation • Line-size based fitting resistances are used to determine fitting friction losses • A single average value for the pressure drop across cooling water usage components in any area is defined in the Preference worksheet • Pressure at junctions, where flows meet, is common to junction streams • Overall circuit pressure drop comes from a stepwise calculation across all junctions • An addition head loss due to cooling tower elevation completes the pressure drop determination It is possible that the limiting line size for branch and area headers may be too small for some circuits with large flows. This would result in a cluster of two or more parallel lines. To alleviate this condition, consider increasing the limiting line size. Projects with a Prior Cooling Water Utility Model Area The cooling water model will allow a single cooling water utility area of its making in a project. If a project contains a prior area, the model will detect its presence and defer action until the user decides to load a new cooling water model design. Choosing to load will delete the prior area and the new one will be loaded. Is the choice is not to load, the model worksheets are closed with a return to the normal view. Cooling Towers: Terminology and the Defining Stream Temperatures Figure overview_4.8 shows a cooling tower with air and cooling water streams and their temperatures. Terms used in the cooling tower industry, illustrated in Figure 4.8, are: 10 Analyzer Utility Modules 339 • Cooling tower: a device used to cool water by the countercurrent action of ambient air against a downward flowing stream of water to be cooled. The cooling process involves the cooling of entering water by evaporative cooling of water and sensible heat to a much lesser degree • Cooling water supply stream: cooling water supplied to heat exchangers for purpose of cooling process streams • Cooling water return stream: cooling water streams leaving heat exchangers, combined for return to a cooling tower • Range: cooling water return temperature, Tr – cooling water supply temperature, Ts, directly related to the heat duty • Approach Gradient: the difference between the wet bulb air temperature and cooling water leaving the cooling tower. Theoretically, the cooling water temperature can not drop below the air wet bulb temperature. For a given cooling water flow rate, as the approach gradient decreases, the cost of a cooling tower will increase. Notes to Analyzer Utility Model (AUM) Users: Cooling Water utility resources that must accounted in the Analyzer Utility Model (AUM) should be named either: Cooling Water or "Cooling Water xx" where: xx can be two digits ranging from 01 to 99, for example, Cooling Water 01 User created utility resources that do not adhere to this format (for example, CW, Sea Water, Cooling Water o3) will not be identified as cooling water streams and will be excluded from AUM's cooling water analysis. Cooling water streams that are not associated with any equipment, will be assigned to the Area with the maximum cooling water flow rate. For areas assigned to two or more circuits, the collected unassigned cooling water flow rate will be assigned to the first area in the circuit handling the largest circuit flow rate. Cooling water can either be bought or be made. If it is to be made, the dew point of ambient air added to the lower model limit for the approach gradient will determine the lowest possible deliverable temperature. To ensure that your specified cooling water utility resource streams can be made, please review the limits for the two cooling water models: • CTWCOOLING • CTWPACKAGED 10 Analyzer Utility Modules 340 AUM_Air Utility Design and Scope Generator for Instrument and Plant Air Overview The Air Utility Module automatically and interactively: • selects, designs, and sizes air plant project components that conform to your: o Project scope design basis o Interactive entries for air utility design and configuration preferences • Augments the scope of your project with a list of designed air utility project components in a unique air utility area on the click of the Load button • Interactive session enables a review of results prior to LOAD creates o Status messages, suggestions to alleviate design clashes o Interactive report of equipment and distribution piping design results With the Air Utility Module, you can review, revise, add other project components and/or Run the augmented project to obtain a new project evaluation. The Air utility model can be • • applied to projects that have been created using o Aspen Process Economic Analyzer, Aspen Decision Analyzer o Aspen Process Economic Analyzer within Aspen Process Economic Analyzer or Aspen Process Economic Analyzer Project areas and their project components • • Aspen Process Economic Analyzer/Analyzer projects: o Each group of project components is contained in a unique “Report Group” o A report group is a project area Aspen Process Economic Analyzer projects: You can create 10 Analyzer Utility Modules o A project area o A report group to coordinate a group of project areas o The AUM Air utility module works with each project area and its air requirements 341 Benefits: • You get early design metrics for decision making • Decide what’s best, then trigger the LOAD operation • With LOAD, a new Air utility area will be inserted into your project with its designed list of air system project components • Before LOAD, air system project components are interactively o Selected based on your selection preferences o Designed in accordance with your project basis and air design preferences o Sized o Reported • In a small fraction of the time and effort it takes to do this work in the traditional manner • Change the project scope? Re-run the utility module! How AUM_Air Works General AUM_Air Workflow 1 Press U button to initiate. 2 Select Air Utility. AUM_Air opens in MS Excel 3 Move the supplied Control Center toolbar to the top and click it. 4 Check Status. 5 Review the Guide, page 349. 6 Select and enter Preferences. 7 Check messages, review results in Report. 8 Revise Configuration parts 1 and 2. 498H 10 Analyzer Utility Modules 342 9 Check messages, review results in Report. 10 Click the Load button to close AUM_Air and load the design results into your project. 11 Review Area and components. 12 Run the project, review results. Using AUM_Air Accessing AUM_Air To access AUM_Air: 1 Starting with an open project that has been evaluated, click Run, then click Utility Model. Or, click the U button to access utility models. The Utility Model dialog box appears: 2 Click Air – Instrument, Plant. 3 Click OK. Three actions now occur 1 The model first identifies if a prior Air – Instrument, Plant model area is present in the project. If present, you can choose to Delete the prior area and continue with the model or return to the project. If you click Delete, the utility model will proceed with the design and delay deletion until it is time to load the new results. 2 If no prior Air – Instrument, Plant utililty area is detected, the Welcome screen is displayed and remains present during a time when: a Project requirements are automatically passed to the model b The model prepares an initial design c The model then displays the Control Center worksheet, which links to all other worksheets and provides an indication of success 10 Analyzer Utility Modules 343 (green signal) or failure (red signal) to create an initial design based on default design parameters. 3 4 A Load | Cancel | Minimize dialog box is provided. at the top. This parks the To continue, click the minimize button button box for access during the design phase. Cancel ends the Air – Instrument, Plant model session and returns normal project functions with no change to the project. Note: A Control Center button bar is provided to access the Control Center worksheet from any worksheet. Nine worksheets are presented in a MS Excel framework: • Welcome • Control Center • Guide • Status • Preferences • Config 1 • Config 2 • EquipStats • PipeStats 10 Analyzer Utility Modules 344 The Initial Design On initiation, the Air – Instrument, Plant model reports the status of the design on the Control Center worksheet under Status, and if there are any, identifies clashes on the Status worksheet and, further, on the Preferences worksheet. A Status Report message: Successful. A Load can proceed indicates all is well between project requirements, design parameters, and design methodology. At this point, it is wise to review early design metrics by accessing the EquipStats and PipeStats worksheets. If captured results are acceptable, a click of the parked Load button: • carries the design results into the project • closes the worksheets • returns to the project for evaluation of the augmented project Should the design basis produce a clash with project requirements, error messages and flags are displayed in a top-down succession of worksheets. The first indication is given under Status Report on the Control Center worksheet. The Status worksheet is the central reporting agency, where checks are made and links are provided to source locations in the EquipStats and PipeStats worksheets. To load the Air – Instrument, Plant data into your Icarus project: When you are satisfied with the model and the Status worksheet shows that there are no errors, you can load the Air – Instrument, Plant model into the project. 1 Click the Maximize button dialog box. 10 Analyzer Utility Modules on the parked Load | Cancel | Minimize 345 2 Click Load. The Aspen Icarus Loader appears, showing the progress of loading the XML data into Icarus. When the Air – Instrument, Plant data has been loaded into Aspen Icarus, the following confirmation message appears: 3 Click OK. The Air – Instrument, Plant data is now included in your project. Modifying Air – Instrument, Plant Data When you have loaded Air – Instrument, Plant data in your project, you modify that data using the AUM_Air module. To Modify Air – Instrument, Plant Data: 1 On the main menu, click Run, then click Utility Model. Or, click the U button to access utility models. The Utility Model dialog box appears. Note that the Status column says Loaded. 10 Analyzer Utility Modules 346 2 Click Air – Instrument, Plant. 3 Click OK. The following warning message appears: Note: Clicking Yes does not actually delete the Air – Instrument, Plant data in your project. You can click Yes, modify the Air – Instrument, Plant data, then choose not to replace the previous Air – Instrument, Plant data with the modified data by clicking Cancel on the Load | Cancel | Minimize dialog box. 4 Click Yes. 5 Modify the data to your satisfaction. If you want to replace the loaded data with your modified data, follow the steps below. 1 Click the Maximize button dialog box. 10 Analyzer Utility Modules on the parked Load | Cancel | Minimize 347 2 Click Load. The Aspen Icarus Loader appears, showing the progress of loading the XML data into Icarus. When the Air – Instrument, Plant data has been loaded into Aspen Icarus, the following confirmation message appears: 3 Click OK. The Air – Instrument, Plant data is now included in your project. If you want to keep loaded Air – Instrument, Plant data and not replace it with your modified data, follow the steps below. 1 Click the Maximize button dialog box. 10 Analyzer Utility Modules on the parked Load | Cancel | Minimize 348 2 Click Cancel. The following warning message appears: 3 Click Yes to cancel the loading process. Your original loaded Air – Instrument, Plant data is retained. Guide for the Air Utility Model (AUM) 10 Analyzer Utility Modules 349 SPECS Organization Chart About this SPECS Book 10 Analyzer Utility Modules 350 About an Air Plant Unit 10 Analyzer Utility Modules 351 About Distribution Piping for an APU Methods In the conceptual design phase, lacking a plot plan, this method is used to develop air distribution piping. • Some runs may be long, some short. • Components in the augmented project scope definition may be modified, deleted, new ones added. The following is a brief description of the methods used. • Areas assigned to an APU are collected in the sequence of the project and are assembled in a column-row array • Array dimensions are determined from area dimensions • Row and column dimensions are figured from total area, number of areas and an initial aspect ratio of 3:2 Air Distribution • Piping is developed for Instrument Air as well as Plant Air. • Piping for each service is developed in the same way, except for volumetric flow and line size Distribution Piping • The APU feeds air to the array through a Main Feeder (MF) • The Main Feeder length is defined in Preferences • Two Main Manifolds (MM) are used on extra-wide arrays, els one or none for an array one column wide • Each MM feeds a Main Line (ML) • Main lines feed Branch Lines (BR) • A tee of the Branch line supplies air to an Area Feeder (AF) • Area Feeders connect to Area Headers (AH) • Area headers, for 2-D area types such as Grade, Pad, etc supply air to the I-P transducers, control valves o P&ID information from the original project provide the requirements for I-P and control valve components o Utility station requirements are developed for each area based on anticipated air tool usage and area size • A plant air connection is made off the Area Header Plant for each utility station Area headers, for 3-D area types such as open steel structures, etc supply air to Risers, then Laterals which then connect to I-P transducers and control valves. o 10 Analyzer Utility Modules Utility station requirements are developed for each 3-D type area based on anticipated air tool usage and area size 352 Schematic The following schematic was prepared to illustrate a large project of 78 areas: Configuration of Air Utility Project Components • Project Components • An Air Plant Unit - APU 10 Analyzer Utility Modules 353 • Schematic of an APU • Multiple APUs • Compressor Redundancy Project Components The Instrument and Plant Air Utility Model creates a set of project components in accordance with the needs of your: • Project Scope definition • Design and selection preferences for Instrument and Plant Air Typical components • Air Compressors • Interstage and After-coolers • Air Filters • Air Receivers • Air Dryers • Air distribution piping (instrument, plant air) • Utility Stations (air, water, steam, condensate drain services) • Associated installation bulks would be developed during project run Components are contained in a uniquely defined Area • Area Title contains a unique time and date to differentiate one run from another • Area can be modified or deleted in the usual way using Aspen Process Economic Analyzer, Aspen Process Economic Analyzer/Analyzer An “Air Plant Unit” - APU • Air intake screens • Air intake ductwork • Air compressors o One main compressor at 100% capacity or two at 50% capacity each o Optional standby spare compressor o Optional start-up compressor • Interstage and after-stage coolers • Air receivers o 10 Analyzer Utility Modules Optional TEMA water cooled or fin-fan air cooled exchangers o Optional individual receivers for instrument and plant air or combined receiver o Optional main receiver or two at 50% capacity each o Optional stand-by receiver 354 • Air filters – pre-filter and post-filter, one or more of each • Air dryers - dual tower type (one working, one regenerating) o One main at 100% capacity or two at 50% capacity each o Optional standby spare air dryer o Optional dryer for Plant Air • Utility piping for turbine steam/condensate, cooling water/return • Distribution piping o Instrument and plant air o Utility stations o Cooling water, steam/condensate headers o Interconnects between two or more air plant units Schematic of an Air Plant Unit General Layout 10 Analyzer Utility Modules 355 Multiple Air Plant Units for Multiple Areas One or up to four Air Plant Units to serve area air requirements. Two distribution networks for each APU: • instrument air • plant air Compressor Redundancy: Multiple, Standby, Start-up 10 Analyzer Utility Modules 356 Design Considerations • Units of Measure • Designed Components • Volumetric Air Flow Rate • Equipment Selection and Design o Compressor Model Selection o Interstage and After Coolers; choice of Air Coolers (for rack mounting) Shell & Tube Heat Exchangers o Air Receivers o Air Filters o Air Dryers Units of Measure Values are reported in the Unit of Measure set of the user’s project, in the: • Utility Module interactive worksheets and reports • Augmented user’s project file Air Utility Area • Designated as AUM_Air_ddmmyy_tttt (date and time stamped) • Contains Air Utility system project components Air Utility Project Components Each item is selected and sized: • Area headers for cooling water/return, steam/condensate, instrument and plant air • Air intake screens • Air intake ductwork • Compressors • Interstage coolers • Utility piping for turbine steam/condensate, cooling water/return • Plant and Instrument Air Receivers • Air Pre-filters, After-filters • Air Dryers • Distribution Pipe, Valves, Fittings 10 Analyzer Utility Modules o Distribution circuits: up to four circuits (one to four air plant units) o Distribution piping, for 2D, 3D area types o Utility stations (total number of stations) 357 Instrument Air (IA) Requirements: Air Flow Rate Plant Air (PA) Requirements: Air Flow Rate 10 Analyzer Utility Modules 358 Compressor Model Selection Method Sizes compressor based on • Total project air flow • Number of desired air plant units • Project areas assigned to each air plant unit • Air plant unit redundancy (working spares, stand-by spares) • Specs for start-up compressor Model type is based on compressor air flow rate • Low flow rates – reciprocating • High flow rates – centrifugal • Flow rates less than model minimum -reciprocating Reciprocating Compressor for Low Capacity Range 10 Analyzer Utility Modules 359 Gasoline Motor-Driven Reciprocating Compressor for Low Capacity Range, Stand-by Spare Centrifugal Compressor for High Capacity Range 10 Analyzer Utility Modules 360 Inter- and After-compression stage Coolers Air Filters 10 Analyzer Utility Modules 361 Air Receivers Air Dryers Interactive Specs • Design Basis o Equipment Redundancy o Equipment Configurations o Selection Specs o Design Preferences o Air Distribution • Areas and Air Plant Units • Layout • Air Distribution Configuration o 10 Analyzer Utility Modules Assignment of APUs to Areas 362 User Preferences • User enters specs interactively in MS Excel SPECS workbook • Preferences worksheet– design and equipment configuration basis • o Organized by category o Color coded o Either/or selections are provided with a base (default) value o Numeric selections are provided with a base (default) value o Help messages assist selections o Error messages are issued for out-of-limit or design clash conditions CONFIG worksheets: basis for distribution air piping to areas o Part 1: Assignment of plant air to areas devoid of equipment o Part 2: Assignment of an APU to an area Equipment Redundancy • Main item at 100% capacity • Main item split into two, each at 50% capacity • Stand-by spare • o Optional o Same size as main item or main item at 50% capacity o Power option for stand-by compressors Electric motor drive Large compressors: steam turbine drive Small compressors: gasoline engine drive Start-up compressors only o Optional o Size based on user % of total capacity of main item Equipment Configurations Equipment configuration choices: Combined air train 10 Analyzer Utility Modules 363 Individual Instrument air train Wet or dry plant air train Basis for Design: Preferences - 1 With the exception of item 1 (Conversion of “Quoted cost” items ….) where no default value is provided, every other user preference is supplied with a default value and minimum and maximum limit values where appropriate. Item 1 requires user entry for an exchange rate which is used in an air utility internal cost model to evaluate costs of air intake screen/filters. 1 Conversion of "Quoted cost" items to Project Currency Units (PCU) o Exchange rate, Project Currency Units per USD: Note: This entry is required. 2 3 Ambient Air Conditions (one set for all APUs) o Dry bulb temperature o Wet bulb temperature o Atmospheric pressure Air Requirements - Capacity for Instrument and Plant air (one set for all APUs) o 4 Excess capacity, % Instrument air Plant air o Air system leakage, % o Install utility stations? o Number of utility stations, % adjustment Air intake screens/filters (uses an AUM_Air cost model) 10 Analyzer Utility Modules o Air to media ratio o Adjustments to model estimate Cost Hour to install 364 5 Weight Compressors (one set of specs for all APUs) Main compressor: o o o o Main compressor One at 100% capacity or two each at 50% capacity Limiting flow rate for a single main compressor, % of model maximum flow Stand-by spare compressor Install? Driver type (electrical or other: turbine, gas motor) Start-up compressor Install? Minimum flow rate to qualify for installation Running time Interstage Coolers Type: • Water cooled (small: Pre-engineered type or large: TEMA BEU) • Air cooled (AIR COOLER) Cooling water inlet and rise temperature Air temperature rise for fin-fan air coolers Notes: If low capacity type is selected, may generate multiple low capacity compressors High capacity compressors may require project mid- and/or high voltage power distribution levels. o 6 7 Utility services for compressors Steam lines: run distance from boiler house to turbines Cooling water lines: run distance from cooling water plant Air Receivers o Common or separate receivers for instrument air and plant air? o One main receiver at 100% capacity or two, each at 50% capacity o Install a stand-by spare? o Horizontal or vertical vessels? o Maximum diameter o Maximum tangent-to-tangent length o Instrument air supply time during emergency shut-down o Plant air supply time during emergency shut-down Air Dryers (Dual Bed–one working, one regenerating) 10 Analyzer Utility Modules o Common air dryer for instrument and plant air? o Is plant air to be dried? o One main dryer at 100% capacity or two, each at 50% capacity 365 o 8 Air Filters o o 9 Air purge rate Instrument air Number of pre-filters Number of post-filters Plant air Number of pre-filters Number of post-filters Distribution piping o Minimum line size for air piping o Distance from APU to process area o Typical tie-in run length from one APU to another Configuration Layout Method and Distribution Basis for Air Utility Model Piping o Layout and primary distribution piping is based on the specs for all areas assigned to an APU o Area feeder and header, risers, laterals are based on area specs Area layout in lieu of a project plot plan o Project areas are arranged in project sequence o Each area is given an ID code based on its report group and area number 10 Analyzer Utility Modules Example: • Report group 2 “Solvent Recovery” • Area 4 description: “Distillation” • Is given an ID code of 100 x 2 + 4 = 204 • ID code 204 is characterized by its report group name and area description o Areas are placed in a rectangular array according to the total number of areas with an initial aspect ratio of 2:3 (fewer columns than rows) o Column-row arrangement is modified to obtain a row-column balance o A branch line is run across each row with area feeder take-offs to each area in a row o Area headers (and risers and laterals for 3D area types) connect to individual project components in that area o Branches are fed using a Main Line o Main Lines are fed by Main Manifolds for wide arrays o Main Manifolds are fed by a Main Feeder from the Air Plant Unit 366 APU Configuration: o Choose default (one APU for all) or assign each Report Group to one of four APUs Example layout – group of areas served by APU “A” Circuit Preferences: Configuration of APUs • Worksheet provides a list of Project Areas and air consumption • Configuration in two parts: • o Part 1: enables areas with no Instrument air requirements to be provided with plant air, else no air is provided o Part 2: enables each area to be assigned to an APU Initial configuration: all areas are assigned to APU “A” o • Design results are presented for the initial configuration Revised configuration: use of up to four (4) APUs o 10 Analyzer Utility Modules Design results are presented for the revised configuration 367 Sample Layouts: One APU Sample Layouts: Multiple APUs Design Methods • Sizing Distribution Piping • Schematic of Distribution Piping Basis for Sizing Air Distribution Piping • Configuration (IA = instrument air; PA = plant air) 10 Analyzer Utility Modules 368 • o Assignment of an APU to Project Areas o Initial configuration: all are areas assigned to one APU o APU Air flow for IA and PA is determined from sum of area usage requirements o Air Module uses a built-in layout model to estimate air distribution piping line lengths o Each line type is assigned an “Iso” with valve and fitting counts, expansion loops for long runs o Areas provides air flow requirements for each line o Lines are sized based on air consumption and a pressure drop of 1 PSI per 100 ft [22.6 KPAG/100 M] or less with a minimum line size as defined in Preferences o Design pressure: 150 psig [1350 KPAG] Sizing Air Distribution Piping to Project Areas 10 Analyzer Utility Modules 369 Distribution for a 3D-Type Area Sample AUM_Air Worksheets Displayed below are sample AUM_Air worksheets. Note the following details about AUM_air and these sample worksheets: • sheets are non-functional • all worksheets visible to the user have the version number printed at the bottom of the sheet • the project illustrated is Aspen Process Economic Analyzer ETOH Sample Project • except for currency and exchange rate, sheets are in the user's units of measure defined in the user's project specs o currency is referred to as PCU - project currency unit o you must enter an exchange rate when opening a project for the first time. The exchange rate value will be "remembered" on opening the project thereafter o ControlCenter, Status and Preferences sheet will always show an error because you must enter an exchange rate for the currency of the project (hyperlinks lead the you from ControlCenter to Status to Preferences to the item to be revised) o on entering a proper value, the error message is not displayed List of AUM_Air Worksheets • Welcome • ControlCenter 10 Analyzer Utility Modules 370 • Guide • Status • Preferences • Config_1 • Config_2 • EquipStats • PipeStats Welcome Worksheet Control Center Worksheet 10 Analyzer Utility Modules 371 Guide Worksheet 10 Analyzer Utility Modules 372 10 Analyzer Utility Modules 373 10 Analyzer Utility Modules 374 10 Analyzer Utility Modules 375 10 Analyzer Utility Modules 376 Status Worksheet 10 Analyzer Utility Modules 377 10 Analyzer Utility Modules 378 Preferences Worksheet 10 Analyzer Utility Modules 379 10 Analyzer Utility Modules 380 Configuration Part 1: Assignment of Plant Air to Areas Not Requiring Instrument Air Configuration Part 2: Assignment of Areas to an APU 10 Analyzer Utility Modules 381 Note: For clarity in this documentation, the following screen shot is shown below the one above it. On the actual Config 2 Worksheet, they are side by side. Report – Equipment Component Stats 10 Analyzer Utility Modules 382 10 Analyzer Utility Modules 383 Report – Pipe Stats 10 Analyzer Utility Modules 384 11 Evaluating the Project Running a Project Evaluation After all the process simulator data has been properly mapped and defined, you are ready to run a project evaluation. The project evaluation produces capital costs, operating costs and investment analysis reports. If any of the components are modified, the evaluation process must be re-run. To run a project evaluation: 1 Click on the toolbar. – or – On the Run menu, click Evaluate Project. The Evaluate Project dialog box appears. The dialog box shows the default Capital Costs report file name, Cap_Rep.ccp. This is the report reviewed in Icarus Editor. If you want it to have a different name, type the file name in the Report File field. 2 Click OK. If you are using the default Preferences, Aspen Process Economic Analyzer scans the project specifications for errors and/or inconsistencies and any 11 Evaluating the Project 385 found are listed in the Scan Messages window. Note: You can select in Preferences to skip the scan for errors (see page 48). X49H X There are four types of messages: Scan Message Description/Importance Level INFOrmational For your information WARNing Design can be produced, but you are alerted to problems ERROR A design or cost cannot be produced for an item FATAL Rare instance for extreme problems You have the option to continue or stop the evaluation process (except in the case of FATAL errors, which stop the evaluation process). You should carefully review these and fix any problems before proceeding. When the project evaluation is done, Aspen Process Economic Analyzer lists all errors found in the capital cost evaluation for your reference. If you are using the default Preferences, Aspen Process Economic Analyzer automatically displays the Investment Analysis spreadsheets in the Main Window when the evaluation is complete. See “Reviewing Investment Analysis” on page 439 for a description of these spreadsheets. X50H X Note: You can select in Preferences not to have Aspen Process Economic Analyzer automatically display the Investment Analysis (see page 48). X501H 11 Evaluating the Project X 386 Reviewing and Revising Process Economics in the Analyzer Economics Module The Analyzer Economics Module (AEM) includes an interactive economic evaluation workbook, that allows you to review economic, scheduling, and manufacturing premises and see the impact of revisions to those premises. It displays in Excel key economic information over the project timeline to help you evaluate projected operations and the return on investment. Loading the Analyzer Economics Module (AEM) To initiate an economic scenario, first load the AEM. To load AEM: 1 On the Run menu, click Decision Analyzer. 2 On the Decision Analyzer dialog box, mark the Develop Detailed Process Economics Reports check box. 3 Enter the desired reporting currency symbol to use for the reporting of all costs. 4 If the plant location currency is different from the currency used on the reports, enter the exchange rate as the ratio of Report Currency/Plant Location Currency. 5 Click OK. In Excel, two workbook files open: SPECS and RESULTS. 11 Evaluating the Project 387 Overview of Workbooks In addition to showing you the economic analysis of the current project basis, the workbooks allow you to instantly see the impact that revisions to the basis will have on economic measurements. For example, you can revise the required working capital percentage on the Project Input worksheet in SPECS and, as a result, the Cash Flow bar chart on the Figures worksheet in RESULTS will change to reflect this revision. This is explained in detail in the “Revising Premises” section, page 397. X502H X SPECS Workbook The SPECS workbook consists of the following worksheets, which you can navigate by clicking the sheet tabs at the bottom of the workbook window: Guide The Guide provides you with an online reminder of helpful information, which you may refer to during an interactive scenario session: • Purpose of Analyzer's Economics Module (AEM) and what AEM does. • The three classes of information from which AEM works. • The two workbooks for new scenario premises. • Details on the worksheets containing input. • Details on the worksheets containing results. • Strategy - how to use this module effectively for evaluating business and economic options. Control Panel The Control Panel allows you to revise high-level stream premises. It features spinner controls and reset buttons, enabling you to change unit prices and instantaneously see the resulting economic metrics and graphed results. 11 Evaluating the Project 388 Key economic metrics displayed include: graphs of net present value (NPV) and annual production revenue, payout date, Internal Rate of Return (IRR), NPV over project lifetime, gross, operating and net revenue margins. Decision Center The Decision Center is AEM's navigator. It enables you to move quickly across all of AEM's user-interactive worksheets, all of which are included in horizontal format. To view all the worksheets in a vertical format, use the DC_V worksheet. Both the horizontal and vertical formats enable you to quickly locate high level and lower level categories and the ultimate worksheet locations. Important error messages are displayed on the Decision Center header. An NPV graph displays the current state of the scenario including high-level error messages with pointers to error locations. DC_V This worksheet contains the same content as the Decision Center worksheet in a vertical format. Input Worksheets The two input worksheets are for user-interactive revisions to premises. They define your economic scenario. Revisions are immediately reflected in the Status, Statements, EPC, and Figures worksheets. See page 397 for information on revising economic premises. X503H 11 Evaluating the Project X 389 Project Input In the Project Input worksheet, you can revise the schedule, time periods, capital investment, cost of capital investment, phase durations, capital cost parameters, manufacturing cost parameters, operating labor and maintenance cost parameters, general investment parameters, and escalation. The following is an excerpt: Stream Input In the Stream Input worksheet, you can revise the stream factor to determine the impact of turndown, turnarounds or a proposed expansion; split production into a domestic and export stream with their associated unit prices; revise prices of byproducts, raw materials, and utilities. An important aspect of the Stream Input worksheet is the use of periodically changing values of stream factor, unit costs and percent to export. This feature will enable you to study the impact of market cycles and identify economic threats and opportunities related to production over the life of the project. Status Worksheet View the Status worksheet for a quick summary of which values on the input worksheets have been revised, need correction, or are incomplete. 11 Evaluating the Project 390 11 Evaluating the Project 391 The Status worksheet also displays a panel board graph of Net Present Value (NPV) and summary status report of project and stream input conditions and major economic indicators to help guide the analyst. Capture Worksheet The Capture worksheet and its initiating buttons enables you to review and capture highlights of up to 50 economic scenarios. A set of buttons is provided to initiate the capture of current scenario highlights in advance of working on the next scenario. RESULTS Workbook The RESULTS workbook consists of six worksheets, which you can navigate by clicking the sheet tabs at the bottom of the workbook window. The following is an overview of the worksheets. EPC Worksheet The EPC worksheet provides before and after information regarding the engineering, procurement and construction aspects of your project. The term “before” refers to the state of your project based on your initial premises, prior to interactively changing from one scenario to another in Analyzer’s Economic Module. The EPC workbook provides costs in both the currency of the plant location and a user-defined “reporting currency. For example, if your project were modeled using the European Union country base (EU, currency in Euro) and you wished to see costs reported in Euro for a project relocated to Mexico (reporting currency in k-Peso), you could define the reporting currency to be Euro and enter the desired exchange rate between the Euro and k-Peso. You would define the reporting currency and exchange rate along with the relocation country, at Run time. The EPC worksheet would report plant location costs in both Euro and k-Peso. This worksheet currently provides the only connection between costs in the country base currency and plant location currency. The EPC worksheet provides the following information: • EPC results based on the initial premises (before the scenario) 11 Evaluating the Project o Status of stream data o Exchange rate used to compute plant location costs in the country base currency o Summary costs, man-hours in both plant location and country base currencies o EPC start and end dates o Breakouts of costs and man-hour for direct materials, engineering and construction and project indirects. 392 • EPC scenario results and key economic measures 11 Evaluating the Project o Economic measures: NPV, IRR, payout time, average annual production over the life of the project o Summary and detailed cost and man-hour information resulting from changes during the interactive session. 393 Project Basis The Project Basis worksheet provides project name, project description, simulator type, capital cost evaluation and parameters, time periods, construction schedule, manufacturing cost parameters, operating labor and maintenance cost parameters, general investment parameters, escalation, cost summary, and EPC details based on your initial economic premises. The following is an excerpt: Design Basis The Design Basis worksheet provides summary-level presentations of income, product revenue, manufacturing costs, margins, raw material costs, utility costs, and earnings based on your initial economic premises. 11 Evaluating the Project 394 The following is an excerpt: Statements Worksheet The Statements worksheet, like the EPC, Status and Figures worksheets, shows results of changes made in the Input worksheets. • Timeline of events (dates, periods). • Payout time, IRR, NPV. • Present values for individually selected production periods. • Period-to-period statements with a display of results for a selectable production period: income-expense statement, summary cash flow statement, capital expenditures statement, margins, and NPV graph. The following is an excerpt: 11 Evaluating the Project 395 Figures Worksheet The Figures worksheet, like the EPC, Status and Statements worksheets, shows results of changes made in the Input worksheets. • Flows, by Calendar Period: Net and Cumulative Cash Flow, Margins, Gross and Operating and Net Income as a % of Revenue, Product Revenues: Domestic and Export. • Production: Domestic and Export. • Distributions, for a selected Production Period: Product Revenues, Manufacturing Costs, Operating Costs, Fixed Charges. The following is an example of one of the distribution graphs on the Figures worksheet: 11 Evaluating the Project 396 Revising Premises The premises on which an economic scenario is based can be modified on the Project Input and Stream Input worksheets. The results of modifications are immediately reflected on the Status, Statements, and Figures worksheets. Note: Revisions made in the workbook have no impact on the actual project basis. To revise premises: 1 Select either the Project Input or Stream Input worksheet. 2 Go to the Select field of the item you wish to change. Pressing TAB moves the cursor to the next field, while pressing CLEAR+TAB moves the cursor to the previous field. You can also use the mouse and arrow keys. The Select field can contain one of the following symbols (not case-sensitive): Enter To denote B Use of base value. R Use of revised value. P Use of period-to-period values on the Stream Input worksheet. For example, changing the symbol from “B” to “R” acts as a toggle between the base and revised value. 11 Evaluating the Project 397 In the event a symbol is not entered, the base value will be used. 3 As this is an exercise in revising premises, enter “R” (or “r”) in the Select field. 4 Go to the input field and enter the new value. For percentage values, simply enter the percentage value. If 0.2% is to be entered, enter 0.2. If 50% is required, enter 50. If a negative value is required, for example to indicate construction is to begin 0.5 periods early, enter a negatively signed value, –0.5. As you make revisions, notes and other messages are provided to assure data integrity. Each line item of data entry has at least one status “flag.” Informational and other messages are provided to guide you in preparing a consistent set of premises. Revised value of 10.00% will be used. Flag field displays “?” and Status of Revision field displays “FIX!” because “r” has been entered without a revised value Base value will be used As soon as you move from the revised field, the revision is reflected in the Status, EPC, Statements, and Figures worksheets. Note: Viewing the workbooks in a split screen arrangement lets you instantly see the results of modifications. To do so, click Arrange on the Window menu, select Horizontal, and click OK. You will likely need to adjust the zoom to about 50%. Keep ECOSYS.xls minimized. For example, if you revise the required working capital percentage on the Project Input worksheet (shown in window at the top of the split screen pictured below), the Cash Flow bar chart on the Figures worksheet (shown in the lower window) will change. 11 Evaluating the Project 398 Color Coding • Base Values: green background, black text. • Revised Values: blue background, black text. • Status Values: yellow background, red text. • Text Notes: blue text. • Error Messages: yellow background, red text and flag symbols. • Dates of key events: blue background, red text. Saving AEM Workbook To save changes to AEM worksheets, it is recommended that you save all workbooks by closing Excel and answering Yes when prompted to save. Saving the worksheets individually has been found to result in an error when re-launching AEM. Discussion of Economic Premises The AEM workbooks organize economic premises into two main categories: project and stream input. This section describes the concepts behind the various parameters. Project Input As described previously, base values are listed to the right of the item category. The Select field and Enter Revised Base Value field enable alternate studies. First, enter either an “R” (not case-sensitive) in the Select field to revise the base value. Then enter a revised value in the Enter Revised Base Value field. You can then enter a “B” (not case-sensitive) in the Select field to 11 Evaluating the Project 399 switch between revised and base value. The Value Used field shows the current status of your selection. The following provides additional information about the individual parameters. Scenario Reporting • Title and date data: will be displayed in the headers of the various worksheets and in the footer of the Status worksheet. • Currency for Scenario Reporting: every cost value in the Economic Analysis workbook will be in the Reporting Currency and converted from the plant location currency by the designated exchange rate. • Plant Location Currency: costs in country base location currency are developed by the Icarus Evaluation Engine (IEE) and are revised by Analyzer’s Relocation Module (ARM). Costs in the plant location currency are reported only in the EPC worksheet if the user elects a reporting currency. • Reporting Currency: this currency is defined upon entering the Analyzer’s interactive Economics Module along with an exchange rate relative to the plant location currency. The exchange rate may be changed, within limits, in the Project Input worksheet. This will enable a user to trend a project over a period of time, should exchange rates vary from the initial premise. Costs in the reporting currency are reported in all worksheets. • Exchange rate: number of currency units of Reporting Currency per unit of Plant Location Currency. The exchange rate may be modified in the Project Input worksheet to reflect a more current or anticipated future value. • Reporting of Cash flows: in millions of reporting currency units. Schedule A timeline is established with a calendar start date to enable the study of economic cycles and report the timing of events. A base calendar start date is automatically generated to accommodate the base start date of engineering. However, as new premises are added, the lead-time between start of calendar and start of engineering may be too short to accommodate other efforts such as studies and changes to the fixed capital investment. Or, you may wish to base your reporting calendar on a calendar year basis or your company’s fiscal year. Once you select the start date of the reporting calendar, you might wish to review your initial premise for the start date of engineering. The engineering start date may be modified as well as the calendar start date. Messages are provided in this section for lead-time, pre-planning time and float to help you to establish timing of other events (see next section on Capital Investment). • Start Date of the Reporting Calendar: defines (a) the project timeline, (b) enables the escalation to the start date of the calendar of costs entering the workbook from Analyzer that are founded on the “System Cost Base Date”, and (c) enables the dating of tasks and events, including: 11 Evaluating the Project o Strategic planning and decision engineering o Contractor’s engineering and procurement 400 o Construction delay/early start of construction o Plant Start-up o Start of Production o Payout o End of production, salvage of fixed capital investment (FCI), return of working capital, salvage of catalyst and chemicals, etc. • Start Date of Engineering. • Status of the calendar: lead time, planning time, float time and other helpful status messages. Time Period • Period: the designated period is a year. Only yearly periods can be accommodated with this release. • Hours per period: determines stream factor, stream flows per period. Your initial premise may be revised in the Stream Input worksheet. Capital Investment • Decision Engineering Studies: duration is developed from the cost entry and placed on the timeline. • Owner’s Engineering: duration is developed from the cost entry and placed on the timeline. • Increment/Decrement to FCI (fixed capital investment, also known as total installed cost, total project cost) at the System Base Date: enables studies of FCI such as the trade-off between inside and outside battery limits (ISBL/OSBL), plant capacity (with associated change in stream factor – see Stream Input), and impact of FCI changes during engineering on process economics, etc. Consider two uses of this feature (1) to determine the impact on IRR and NPV of a 10% increase in capital cost and (2) making a utility stream by adding more capital and setting the utility stream cost to zero. A change here will impact the phase duration of engineering, procurement and construction as well as their expenditures along the timeline. In the AEM workbooks, FCI undergoes a number of adjustments from the time it is evaluated by the Icarus Evaluation Engine (IEE), as follows and as reported in the EPC worksheet: 11 Evaluating the Project o Initial evaluation in Analyzer performed by applying design and cost specifications to the list of project components for the specified production capacity of the process facility and plant location. o In the AEM workbooks: Currency revision of FCI from the Plant Location Currency to the Reporting Currency, using exchange rate first established during Plant Relocation and then under Scenario Reporting in AEM. Escalation from “System Base Date” to the Start Date of the Calendar. Percentage Increment/Decrement adjustment (this section). 401 • Escalation of engineering, materials, construction to the period of expenditure as determined by the duration of each phase, progress of each phase duration, and position along the timeline. Start-up costs: included as a capital expense, range of typical values: 8% to 10% of FCI. Phase Durations • Duration of EPC Phase: base value, from Analyzer (CPM-based planning schedule). • Delay or Early Start of Construction: enables study of impact of delay prior to start of construction or early start. The planning schedule includes early start. Analyzer splits construction from EPC duration to enable delays to be studied. A negative delay value results in an early start. As phase durations are revised, so too are dates of key events along the timeline. As stream flows and expenditures are moved along the entire time line by changes in phase durations (or other revisions), they will be evaluated for escalation or unit costs/prices that are assigned to each period. Capital Cost Parameters • Working Capital, as a percentage of fixed capital investment (FCI). The range of typical values is 10% to 25% of FCI (10% to 20% of the total investment, i.e. the sum of FCI and working capital), but you can enter any percentage. A range of typical values is provided for guidance. • Catalyst and Chemicals: for the initial charge, as a percentage of FCI and salvage value at the end of production. • Patents and Royalties, as an initial fee and/or fee, escalated for each period of production and figured on the production for each period. • Land: range of typical values: 1% to 2% of FCI. Manufacturing Cost Parameters • Operating Charges: if no base value is provided, Analyzer will estimate and report a cost value based on Plant Operating Labor. It will split operating charges into costs for Operating Supplies and Laboratory Charges, which values may be revised individually as a percentage of Operating Labor. • Range of typical values o Operating Supplies: 10% to 20% of Maintenance o Laboratory Charges: 10% to 20% of Operating Labor Note: Typical ranges do not define limits on user entry. Operating Labor and Maintenance Costs • Number of Shifts: base value determined by project components, type of facility, etc. might be revised, especially if Increment/Decrement is made to FCI. 11 Evaluating the Project 402 • Operator: number of operators and hourly rate may be revised from the base value; Total Operating Labor Cost is displayed. • Supervision: Number of Supervisors and hourly rate may be revised; Total Supervision Cost is displayed. • Maintenance: Cost/period is displayed and is reported as a percentage of FCI, which % may be revised; range of typical values: 2% to 10% of FCI. General Investment Parameters Base values for the following items come from your system input and may be revised in AEM: • Tax Rate. • Interest Rate: used in calculating net present values and payout time. • Economic Life of Project: defines the time for depreciation and should be the same as production life. • Salvage Value, as a fraction of the initial capital cost. This value is recovered at the end of the project life. • Depreciation Method: select from Straight Lines, sum of the Digits, Double Declining (Balance). Escalation Base values of the following items come from your system input and may be revised. • Project Capital Evaluation, a single value is expanded in AEM for individual treatment of expenditures along the calendar timeline for: o Engineering o Materials o Construction • Product Escalation: individually for domestic and export product; periodto-period price/cost values take priority over escalation. • By-products: period-to-period price/cost values for an individual by-product take priority over escalation for that by-product. • Raw Materials: period-to-period price/cost values for an individual raw material take priority over escalation for that raw material. • Utilities: period-to-period price/cost values for an individual utility take priority over escalation for that utility. • General: for remaining categories. Stream Input This worksheet allows you to revise base values (assigned or default) for product, by-product, raw material and utility streams. Either a single value, applicable to every period (subject to escalation if a cost), or a period-toperiod value (not subject to escalation) may be assigned. Indicate use of base (“B”), revised (“R”) for a single value for all periods, or individual period-toperiod values (“P”). Symbols are not case-sensitive. 11 Evaluating the Project 403 Phases Along the Project Timeline The following resulting values guide other input specifications. • Phase. • Phase duration. • Start date. • Fraction of a period devoted to each phase along the calendar timeline, which includes the following: • o Start date of each period. o Year: displayed with each section to maintain integrity of period-to-period input data. o Calendar Periods: Period (year) from the start of basic engineering. o Periods of Operation – year from start-up. Start-up, Payout, Shutdown dates. Production Operations Stream Factor, to study the impact of turndown and expansion. Production Price of domestic and export product and percentage of production devoted to export product. The production capacity is reported for reference. By-Products Price of each by-product. By-product rates are reported for the designated production capacity. The current version is limited to reporting 25 byproducts. Raw Materials Price of each raw material. Consumption of each raw material is reported for designated production capacity. The current version is limited to reporting 25 raw materials. Utilities Price of each utility; for ISBL/OSBL studies, consider revising an ISBL utility stream cost in lieu of its production by an OSBL unit and revision of the FCI (Project Input>Capital Investment>Increment/Decrement to FCI) to account for the OSBL unit’s FCI – Consumption of each utility is reported for designated production capacity. 11 Evaluating the Project 404 Reviewing Results in Aspen Icarus Reporter Accessing Aspen Reporter To access Aspen Icarus Reporter: 1 Click on the toolbar. – or – On the View menu, click Capital Costs View. The Select Report Type To View dialog box appears. 2 Keep Interactive Reports selected and click OK. The Reporter imports and loads the reports from Aspen Process Economic Analyzer. 11 Evaluating the Project 405 After the reports are loaded, the Aspen Icarus Reporter window appears. 11 Evaluating the Project 406 Aspen Icarus Reporter Menu Bar File Menu Import Data – Import project reports. See page 428 for instructions. X504H X Run Report – Run selected report. See pages 408 (Standard reports), 421 (Excel reports), and 416 (HTML reports) for instructions. X50H X507H X X506H X X Open Workbook – Open the last Excel workbook created. See page 424 for instructions. X508H X Create User Database – Export SQL database. See page 429 for instructions. X509H X Exit – Close Aspen Icarus Reporter. Trend Menu Add Trend Data to Database – Add the trend data from the project reports currently loaded in Aspen Icarus Reporter to the trending database. See page 425 for instructions. X510H X Create New Trend in Excel – Export trending database to Excel. See page 426 for instructions. X51H X View Existing Trend Data – Open the trending data workbook in Excel. See “Data Trending,” pages 425 through 428, for instructions X512H X X513H X Clear All Saved Trends – Clear the trending database. See page 425 for instructions. X514H X Which Report Mode? There are four report modes: Standard reports, HTML reports, Management reports, and Excel reports. All but Management reports present Capital Costs and Design and Basis reports. Management reports contains snapshots of project data frequently requested by project management. Standard, HTML, and Excel reports do not just present the same data in different applications. Because of the differing capabilities of the applications, data is presented differently in each. The choice of mode may depend upon what you wish to do with the data at a particular time. Standard Reports With Standard reports selected in the Report Mode section, the Reports section displays a tree-structure grouping of standard reports. Report Descriptions Open the necessary category and sub-category folders and click on a report to display a brief description of that report in the Description section. 11 Evaluating the Project 407 Aspen ICARUS Reporter displays a description of the selected report. See page 412 for descriptions of all Standard reports. X51H X Opening a Report Not all of the reports contain each of the features described in this guide. For example, the Contents view only appears on reports with multiple sections. In order to see all the features described, select the Contractor – COA Summary report located in the following folder: Capital Cost Reports\Direct Costs\COA Summaries To open the selected report: • Click the Run Report button . - or On the File menu, click Run Report. - or Double-click on the report. The report window appears. 11 Evaluating the Project 408 Navigating If there are multiple sections, a tree-structure Contents view appears on the left side of the window, allowing you to jump to a section simply by clicking the section in the Contents. The arrow buttons on the toolbar let you page through the report: Next Page Previous Page Last Page First Page Because the last page of a report usually contains the totals, clicking the Last Page button is a convenient way to access them. Magnification To change the magnification level: 1 In the Magnification box, click menu. 11 Evaluating the Project , then click the desired level from the 409 Note: You can also click directly in the Magnification box (without clicking ) and then zoom in and out using the up and down arrow keys on your keyboard. 2 When viewing the report at large magnification, you may wish to hide the Contents view by clicking the Toggle Group Tree button more room for the report. . This makes Segregating a Cost Section If the cursor changes into a magnifying glass icon when placed over a cost section’s title or totals, you can double-click to open a separate tab window containing only that cost section. For example, under Civil in the Contractor – COA Summaries report, the cursor changes into a magnifying glass when placed over the Concrete cost section’s title or totals. Double-clicking on this cost section’s titles or totals opens a separate tab window. 11 Evaluating the Project 410 Here, the Equipment cost section is displayed in a separate tab window, where it can be viewed and printed apart from the rest of the report. Searching To search the report: 1 Click on the toolbar. 2 Type the text string for which you want to search. 3 Click Find Next. The next instance of the text string is framed in red. Printing To print the report: 1 Click on the toolbar. The Print dialog box appears. 2 Make any desired changes to the default settings; then click OK. 11 Evaluating the Project 411 List of Standard Reports 11 Evaluating the Project 412 11 Evaluating the Project 413 11 Evaluating the Project 414 HTML Reports With HTML reports selected in the Report Mode section, the Reports section displays a tree-structure grouping of HTML reports. Report Descriptions Open the necessary category and sub-category folders and click on a report to display a brief description of that report in the Description section. 11 Evaluating the Project 415 Opening an HTML Report To open the selected report: 1 Do one of the following: • Click the Run Report button. – or – • On the File menu, click Run Report. – or – • Double-click on the report. A status window tells you when the export is complete and asks if you would like to view the report now. 2 Click Yes. Your browser displays the report. 11 Evaluating the Project 416 Note: Generating the report as an .htm file allows the report to be sent in an e-mail. Management Reports With Management Reports selected in the Report Mode section, the Reports section displays a tree-structure grouping of Management reports. These reports are intended to serve as snapshots of the project scenario. Opening a Management Report To open a Management report: 1 Select the report. 2 Do one of the following: • Click the Run Report button. - or • On the File menu, click Run Report. - or • Double-click on the report. The Management Reports Viewer displays the report. Pictured below is the Detailed Weight Information report, one of the Piping reports in the Discipline folder. 11 Evaluating the Project 417 Other reports, like the Equipment Cost (Total Cost) report shown below, show simply a bottom-line total. Exporting Management Reports to Excel You can export Management reports to Excel. This is particularly useful for when you want to be able to e-mail the report. To export a Management report to Excel: 1 Click Export to Excel on the Viewer’s File menu. Reporter searches for the last Excel workbook to which you exported a report. • If no existing workbook is found, Reporter asks you to specify a worksheet name (see step 3) and creates a workbook – either DefaultWB.xls in the Reporter output folder (if this is your first export to Excel since last rebooting) or a workbook with the file and path name of the last workbook to which you exported since starting your computer. • If an existing workbook is found, the Export to Excel Workbook dialog box appears, asking if you want to overwrite the existing workbook, append the report to the existing workbook, or create a new workbook. 11 Evaluating the Project 418 Select To do this Overwrite existing workbook Reset the existing workbook with the selected report as the only worksheet; any previously created worksheets will be cleared. Append to existing workbook Add the report as another worksheet in the existing workbook; previously created worksheets will be retained. Create new workbook Specify a new workbook in which the selected report will appear as a worksheet. Clicking Create new workbook expands the dialog box to let you select a folder and enter a file name. Note: Do not enter a file extension or period when entering a new workbook name. 2 Make your selection; then click OK. 11 Evaluating the Project 419 3 Enter a name for the worksheet. 4 Click OK. The Export Status dialog box informs you when the export is done and asks if you would like to open the workbook now. 5 Click Yes to open the workbook. Excel displays the report. Excel Reports With Excel reports selected in the Report Mode section, the Reports section displays a tree-structure grouping of Excel reports. 11 Evaluating the Project 420 Report Descriptions Open the necessary category and sub-category folders and click on a report to display a brief description of that report in the Description section. Aspen ICARUS Reporter displays a description of the selected Excel report. Opening an Excel Report To open a report: 1 Select the check box next to the desired report. You can select multiple report check boxes to open multiple reports. Marking a folder’s checkbox will open all of the reports in the folder. 2 Click the Run Report button or click Run Report on the File menu. Reporter searches for the last Excel workbook to which you exported a report. • If no existing workbook is found and this is your first export to Excel during this session, Reporter creates DefaultWB.xls in the Reporter output folder: 11 Evaluating the Project 421 ...Economic Evaluation V7.0\ic_cache\Reporter\Output • If no existing workbook is found, but you have exported from Reporter to Excel since you last started you computer (to a file that’s since been moved or deleted), Reporter creates a workbook with the file and path name of the last workbook to which you exported. • If an existing workbook is found, the Export to Excel Workbook dialog box appears, asking if you want to overwrite the existing workbook, append the report to the existing DefaultWB.xls workbook, or create a new workbook. Select To do this Overwrite existing workbook Reset the existing workbook with the selected report as the only worksheet; any previously created worksheets will be cleared. Append to existing workbook Add the report as another worksheet in the existing workbook; previously created worksheets will be retained. Create new workbook Specify a new workbook in which the selected report will appear as a worksheet. Selecting Create new workbook expands the dialog box to let you enter a workbook path and name. 11 Evaluating the Project 422 Note: Do not enter a file extension or period when entering a new workbook name. After you make your selection and click OK, Excel opens a workbook displaying the report. 11 Evaluating the Project 423 Note: Exporting the report to an .xls file allows it to be sent in an e-mail. AutoFilter Several of the larger Excel reports generated by Aspen Process Economic Analyzer take advantage of the AutoFilter feature in Excel. To view a report that includes AutoFilter: • Open the following report: Capital Cost Reports\Direct Costs\Item Summaries\Combined When AutoFilter is available, clicking next to a column displays a list of all the different entries made in the column. Selecting an entry displays only rows that contain that entry in the column. For example, selecting 105 – Misc. Item Allowance in the COA Description column of the Item Summary Combined report would display only accounts with Code of Account (COA) 105. Selecting Top Ten displays only items that contain one of the top ten most frequent entries. Selecting Blanks (from the bottom of the list) displays only rows that contain a blank cell in the column, while selecting NonBlanks displays only rows that contain a value in the column. Opening Workbook Without Running Report To view the last workbook created without running a new report: • On the File menu, click Open Workbook. 11 Evaluating the Project 424 Data Trending Data Trending facilitates comparison of scenarios by allowing you to review capital cost summaries of different scenarios in a single Excel workbook. If, for example, you created three different scenarios for a project, you could use the Data Trending feature to display the direct costs of each on one spreadsheet, with a separate row for each scenario. Clearing Trending Database Because you only want to compare certain scenarios, the first step is usually to clear the database used to populate the Excel trending workbook. To clear the trending database: 1 On the Trend menu, click Clear All Saved Trends. A confirmation dialog box appears. 2 Click Yes to confirm clearing of the data. The Trending Data Update dialog box tells when this is done. 3 Click OK. Adding Trend Data to Database The next step is to add trend data to the database. To add the current project reports’ trend data to the database: 1 On the Trend menu, click Add Trend Data to Database. 11 Evaluating the Project 425 The Trending Data Update dialog box tells you when Reporter has finished adding the trend data. 2 Click OK. You will need to add the trend data from the project reports of the other scenarios you are comparing. For each of the other scenarios, open the reports in Reporter and complete the Adding Trend Data to Database instructions above. Using Reporter’s import function, you can open the other scenarios’ reports in Reporter without opening the scenarios in Aspen Process Economic Analyzer. See page 428 for instructions. X516H X Creating a New Trend in Excel After you have added the trend data from the Capital Cost reports of the scenarios you are comparing, you are ready to create a new trend in Excel. To create a new trend in Excel: 1 On the Trend menu, click Create New Trend in Excel. The Export to Excel Trending Workbook dialog box gives you the choice of either appending the trend data to the existing file or creating a new file. 2 Make you selection; then click OK. 11 Evaluating the Project 426 The Export Trend Data into Excel dialog box appears. By default, all six capital cost categories are marked. 3 Clear any categories you want to exclude from the workbook; then click OK. The Export Status window tells you when the export is complete and asks if you would like to open the trending workbook now. 4 Click Yes. Excel displays the trending workbook containing a spreadsheet for each of the capital cost categories. Each set of trend data entered into the trending database is displayed on a separate row. (The workbooks for any categories excluded at the Export Trend Data into Excel dialog box are blank). 11 Evaluating the Project 427 5 After having created the trending workbook, you can access it from Reporter by clicking View Existing Trend Data on the View menu. Importing Data into Aspen Icarus Reporter When you have a project scenario open in Aspen Process Economic Analyzer and select Capital Costs (Interactive) from Aspen Process Economic Analyzer, Reporter automatically imports that project scenario’s Capital Cost reports as it opens. However, once you’re at the Aspen Icarus Reporter window, you can import a project scenario’s Capital Cost reports without having the project scenario open in Aspen Process Economic Analyzer. To import a Capital Cost report: 1 Click Import Data on the File menu. The Import Selection dialog box appears. 11 Evaluating the Project 428 2 Use the browse tree to locate the project scenario folder, which should be at: …Archives_Aspen Process Economic Analyzer\[Project]\[Project Scenario] After clicking the project scenario folder, PROJID should appear in the File set to import section. 3 Click PROJID; then click Import. Reporter imports the data. When complete, the selected scenario’s reports can be run from Reporter. Creating a User Database You can export the Icarus SQL Database, listing the Relation attributes used by the Icarus Evaluation Engine (IEE), to a Microsoft Access Database (.mdb) file. ICARUS Reference, Chapter 35, “Database Relations”, defines the ICARUS Database Relations and the different attributes under each. To create a user database: 1 Click Create User Database on the File menu. Reporter searches for the last .mdb file it created. • If the file is not found or if this is your first database creation, the Create User Database dialog box appears with only one Export Option: Create New Workbook. The lower part of the dialog box provides fields for selecting a path and filename. • However, if the last created file is found, the Export Options also include Overwrite Existing Workbook. This option is marked by default, so the lower part of the dialog box is not visible until you select the Create New Workbook check box. 11 Evaluating the Project 429 2 Select a folder, enter a database name, and then click OK. Reporter creates the .mdb file. 3 To review and work with the database, start Microsoft Access and open the .mdb file. Reviewing Results in Icarus Editor Icarus Editor is a fully OLE-compliant, Multiple Document Interface (MDI) text editor program. Accessing Icarus Editor To view Capital Costs in Icarus Editor: 1 Do one of the following: • Click on the toolbar. – or – • 2 T Click Capital Costs View on the View menu. On the Select Report Type To View dialog box, click Evaluation Reports; then click OK. T 11 Evaluating the Project 430 Icarus Editor opens displaying the Capital Cost report. The right-hand pane contains the report and the left-hand pane contains a tree-structure Contents view that lets you jump to sections of the report. Note: Click on the toolbar to turn the Contents view on and off (or click Contents on the View menu). Printing a Single Section The Contents view also lets you print a single section, rather than the entire report. To print a single section: • Right-click on a section; then click the Print button that appears. Icarus Editor Toolbar New – open a new document in the Document View 11 Evaluating the Project 431 Open – open an existing document Save – save current document to disk File Properties – view selected properties of current document Print – print the current document Print Preview – print preview the current document Page Setup – specify how the current document will be printed Cut – cut selected text to windows clipboard Copy – copy selected text to windows clipboard Paste – paste contents of windows clipboard into insertion location Bold – bold selected text Italic – italicize selected text Underline – underline selected text Select Font – specify font for selected text Find (CTRL+F) – find any text string within the current document Preferences – set and save your preferences Toggle Contents – turn OFF/ON the Contents View Cascade – display multiple documents cascaded Tile Horizontal – display multiple documents tiled horizontally Tile Vertical – display multiple documents tiled vertically Help Contents – display on-line help Report Sections Title Page Two title pages are produced. This way, if the report is being printed on fanfold paper, one of the title pages will be produced on a page facing up. 11 Evaluating the Project 432 Features • Estimate Base: financial quarter from which cost basis is derived and date Icarus Evaluation Engine (IEE) was produced. Run Date: Date and time that project evaluation was run. • The currency symbol used in the report. • Telephone numbers to call for technical support. Contract Structure The Contract Structure section provides names of contractors and reporting arrangement. Table of Contents The Table of Contents lists section names and the page number on which each starts. The number of sections may vary depending on the number of Report Groups. If the project contains only one, then there will be only a single summary. If more than one, there will be a separate summary for each, plus a summary for the total project. 11 Evaluating the Project 433 Project Summary The Project Summary provides an overview of project costs. 11 Evaluating the Project 434 Project Data Sheet The Project Data Sheet lists items with separate columns showing userentered values and system default values. Total Manpower Schedule The Total Manpower Schedule shows construction manpower loading based on the CPM Construction Schedule. 11 Evaluating the Project 435 Ways to influence this schedule include: • Adjusting productivities, shifts per day, length of the workweek using the General Rates specifications form and the Craft Rates specifications form. These forms are accessed in Project Basis view under Project Basis\Basis for Capital Costs\Construction Workforce. • Indexing man-hours either at the Project level (Project Basis\Basis for Capital Costs\Indexing) or at the Area level. The number of MEN PER DAY for each vertical bar is generated by summing the labor assigned to all the work items that fall within the period represented by that bar in the barchart. Cash Flow Summary The Cash Flow Summary shows total capital cost spent. 11 Evaluating the Project 436 This barchart schedule assumes that the DESIGN ENG’G AND PROCUREMENT monies are already spent at the start of construction - the curve is not truly tied to the CPM schedule. During construction, capital is then spent for material, direct field labor, equipment rental and subcontract work, Home and Field Office, Start-up, etc., as the cost is incurred. By the end of construction, the TOTAL,AMOUNT given in the Project Summary is indicated here. Operating costs, such as start-up utilities, raw materials, initial catalyst charges, etc., are not included. Project Schedule Data Sheet The Project Schedule Data Sheet lists the fabrication and ship times for equipment items by class and provides barcharts of the following: General Schedule: Balanced display of Basic and Detail Engineering, Procurement and Construction (EPC). Engineering Schedule: Details for Basic and Detail Engineering and Procurement; summary for Construction. Construction Schedule: Details for Construction- others summarized. Contracts Schedule: Schedule for contractor(s). When a single contractor is performing all work, this schedule shows no new information. 11 Evaluating the Project 437 Contract Summary The Contract Summary breaks costs down by contractor. Summaries By Report Group Summaries By Report Group provides the direct material and labor costs and manhours by report group for all areas reporting to that group. List of Equipment and Bulk Material By Area For each Area, the Equipment and Bulk Material List is divided into three sections. First there is the Component List, followed by the Area Bulk Report, and finally the Area Data Sheet. Following the last Area of each Report Group, there are two more reports - the Report Group Summary and the Report Group Equipment Summary. Appendix A- Design Data Sheets Appendix A contains the Design Data Sheets for those items which are heavily designed by the system- fewer items will have Design Data Sheets than are listed in the Component List, above, which lists all user-added components. Since the Design Data Sheet details the design on which the cost and installation labor is based, it is especially useful during calibration of the 11 Evaluating the Project 438 system’s material costs and man-hours. It helps you compare your benchmark item to Icarus’ on an “apples-to-apples” basis. Appendix B- Detailed Bulk Material and Field Manpower Listing Appendix B lists the design and cost details for every component, whether system-generated or user-added. The results are reported in the sequence that the items appear in the Area tree diagram. Appendix C- Bulk Material and Field Manpower Summaryby Report Group Appendix C consists of one summary of the material and manpower manhours and cost for all direct costs in the project. There is one report per Report Group; if there is only one Report Group, then this report is eliminated. It is replaced by the project bill of material (see Appendix D description below). Appendix D –Bulk Material and Field Manpower Summary - Total Project Appendix D is a project bill of material (BOM). The format summarizes total direct costs for all accounts. Due to the fact that the numbers are large, this is the best source of material costs and man-hours for calibration. Appendix E – Direct Material and Manpower Summary by Major Account - Total Project Appendix E lists the Icarus default units of measure as well as any user modifications. Reviewing Investment Analysis You can view the Investment Analysis results generated by Aspen Process Economic Analyzer in two modes: 1 View the results in the Main Icarus Window (ICS spreadsheets). 2 View the results in MS Excel. If you are using the default Preferences, Aspen Process Economic Analyzer automatically displays the four Investment Analysis spreadsheets in the Main Window after you run an evaluation. You can set Preferences so that Aspen Process Economic Analyzer does not automatically display the spreadsheets, in which case you would have to select to view them as described below. 11 Evaluating the Project 439 Viewing Investment Analysis To view the Investment Analysis in the Main Icarus Window (ICS spreadsheets) 1 Do one of the following: • Click on the toolbar. – or – • 2 On the View menu, click Investment Analysis View. Use the tabs at the bottom of the window to move among the four spreadsheets. To view the Investment Analysis in MS Excel On the main menu, click Tools | Options | View Spreadsheets in Excel. 2 Do one of the following: T 1 • Click on the toolbar. – or – • On the View menu, click Investment Analysis View. Note: In the Excel mode, additional spreadsheets are generated that report details with regards to utilities, raw material and products. For instructions to generate customized investment analysis reports, see Using the Reporting Assistant in Excel mode, page 458. X517H X Equipment Summary The Equipment Summary (EQUIP.ICS) contains a list of project components used in the analysis. 11 Evaluating the Project 440 For each component, the summary contains the following information: Area Name: The name of the operational unit area. Component Name: The name of the project component. Component Type: The type symbol for the component. Total Direct Cost: The total direct material and labor costs associated with the project component (including installation bulks), in the project currency. Equipment Cost: The bare equipment cost associated with the project component. Project Summary Project Summary (PROJSUM.ICS) contains a project summary for the capital costs (equipment plus bulks) and schedule. This worksheet also includes operating unit costs (labor wage rates and utility unit costs), utility flow/use rates (steam/water flow rates, etc.) and operating and maintenance costs. Project Summary Input Data The following information on the Project Summary spreadsheet is userentered, except where noted: Project Information Project Name Aspen Process Economic Analyzer project name Project Description Brief description of Aspen Process Economic Analyzer project, from Project Properties Analysis Date and Time The date and time this analysis was performed Simulator Type The name of the process simulator from which process data was imported Simulator The version of the process simulator 11 Evaluating the Project 441 Version Simulator Report File The name of the process simulator report file Simulator Report Date Date and time of the process simulator report file Economic Analysis Type The name of the Icarus system used for the evaluation Aspen Process Economic Analyzer Version Version number for Aspen Process Economic Analyzer system Project Directory Directory path for the current Aspen Process Economic Analyzer project Scenario Name Name of the current scenario (if applicable) Scenario Description Description of the current scenario, from Project Title on the General Project Data form. Capital Cost Evaluation Basis Date Date of capital costs/schedule analysis Country Country basis for the capital costs/schedule analysis Units of Measure Units of Measure for analysis Currency (Cost) Symbol System currency symbol which depends on the selected country basis Currency Conversion Rate Conversion factor between user-selected currency to the currency used by the system internally for the selected Country basis. For example, if the US country basis is selected, the internal system currency is US Dollars. Therefore, all numbers will be reported in US Dollars. However, if a currency conversion rate of 1.5 is specified, all internal values will be multiplied by 1.5 and then reported System Cost Base Date The capital costs basis date of the system. The Adjusted Total Project Cost represents the calculated capital cost of the project (calculated at this base date) escalated to the Start Date of Engineering. Project Type Project type identified on General Specs form Design code Selected design code for equipment Prepared By Identifier for the preparer of the process evaluator Plant Location Location of the plant Time Difference Between System Cost Base Date and Start Date for Engineering Number of days between the date of the system’s Cost Base data (for example, first quarter, 2000) and the project’s start date for basic engineering. User Currency Name User assigned name for the currency User Currency Description User assigned description of the currency User Currency Symbol User assigned symbol of the currency. This is the symbol used for reporting the cost results in 11 Evaluating the Project 442 the reports. Descriptions for the following parameters are provided in more detail under Investment Parameter specifications (page 101). X518H X Time Period Period Description Duration of time Operating Hours per Period Number of hours in specified period Number of Weeks per Period Number of weeks in specified period Number of Periods for Analysis Set to 20 periods for investment analysis Schedule Start Date for Engineering The beginning date for EPC (engineering, procurement, and construction) Duration of EPC Phase The calculated EPC duration in weeks Length of Start-up Period Number of weeks scheduled for start-up beyond the end of the EPC phase Duration of Construction Phase The calculated construction duration in weeks Completion Date for Construction The calendar date for the end of EPC Capital Costs Parameter Working Capital Percentage Percentage of total capital expense per period required to operate the facility until the revenue from product sales is sufficient to cover costs. Operating Costs Parameters Operating Supplies Indicates the lump-sum cost of operating supplies. Laboratory Charges Indicates the lump-sum cost of laboratory charges. User Entered Operating Charges (as percentage) Indicates the user-entered value for total operating charges. Operating Charges (Percent of Operating Labor Costs) Includes operating supplies and laboratory charges. If the user enters a lump-sum value for either “Operating Supplies” or “Laboratory Charges”, the addition of the two values will override the “User Entered Operating Charges” Plant Overhead (Percent of Operating Labor and Maintenance Costs) Consists of charges during production for services, facilities, payroll overhead, etc. 11 Evaluating the Project 443 G and A Expenses (Percent of Subtotal Operating Costs) General and administrative costs incurred during production such as administrative salaries/ expenses, R&D, product distribution and sales costs. General Investment Parameters Tax Rate The percent per period of earnings that must be paid to the government. Desired Rate of Return Indicates the desired (i.e., userentered) return rate, in percent per period, for the investment. Economic Life of Project Indicates the length of time in terms of periods over which capital costs will be depreciated. Salvage Value (Fraction of Initial Capital Cost) The expected value of an asset at the end of its usable life for the company. The difference between an asset’s cost and its salvage value is the amount to be depreciated over the asset’s usable life. Depreciation Method There are four depreciation methods allowed in Aspen Process Economic Analyzer: Straight Line, Sum of the Digits, Double Declining (Balance), Accelerated Cost Recovery System (ACRS). See “Investment Parameters” in Chapter 3 for a detailed definition of each depreciation method. Escalation Project Capital Escalation Rate at which project capital expenses may increase expressed in percent per period. If the addition of Engineer-Procure-Construct (EPC) period and start-up period is greater than one whole period, Project Capital Escalation is used to escalate the capital expenses for periods beyond the first period. Products Escalation Rate at which the sales revenue from products of the facility are to be escalated (increased) in terms of percent per period. Raw Material Escalation Rate at which the raw material costs of the facility are to be escalated (increased) in terms of percent per period. Operating and Maintenance Labor Rate at which the operating and maintenance costs of the facility are to be escalated (increased) in terms of Escalation percent per period. The operating labor costs include operators per shift and supervisory costs. Utilities Escalation User-entered percentages reflecting the anticipated utility price increase each period. Project Summary Output Data The following OUTPUT data is generated by Aspen Process Economic Analyzer : 11 Evaluating the Project 444 Project Results Summary Total Project Capital Cost The total capital cost investment needed for the project. If the calculated EPC period is more than a year, the capital costs expenditure will be spread out over the length of the EPC period. Total Raw Materials Cost The total raw material cost of the facility ex pressed in terms of cost per period. Total Products Sales The total product sales of the facility expressed in terms of cost per period. Total Operating and Maintenance Labor Cost The operating labor (including operators/shift and supervisors/shift) and maintenance labor costs in terms of cost per period. The maintenance cost includes maintenance labor and supplies. Total Utilities Cost The total utilities usage cost expressed in cost per period. Total Operating Cost The total of raw material, utility, operating labor, maintenance, operating charges, plant overhead and G and A expenses. Operating Labor Cost Includes operators per shift and supervisors per shift costs. Maintenance Cost Maintenance cost of the equipment including labor and materials. Operating Charges Includes operating supplies and laboratory charges. Plant Overhead Consists of charges during production for services, facilities, payroll overhead, etc. Subtotal Operating Cost Subtotal cost of raw materials, operating labor, utilities, maintenance, operating charges, and plant overhead. G and A Cost General and administrative costs incurred during production. This is calculated as a percentage of the Subtotal Operating Costs. The costs listed under Project Results Summary are broken down into individual elements under Project Capital Summary: Project Capital Summary Purchased Equipment The total material cost of process equipment and quoted equipment cost items. Material cost is accounted for in the codes of account 100 299. Equipment Setting The total construction labor cost for setting equipment in place. Piping Instrumentation The cost reported for each of these items indicates the total material and construction labor cost calculated for the category. The above cost items may have originated from two sources: Electrical Installation Bulks (please refer to Icarus Civil Steel 11 Evaluating the Project 445 Insulation Reference). Paint User: The user can add project components that create cost items in these categories. The project components may be in the following categories: Plant bulks, Site development and Buildings. Other This item is the total of the following costs: design, engineering, and procurement costs; material charges (freight and taxes); and construction field indirect costs (fringe benefits, burdens, consumables/small tools, insurance, equipment rental, field services, field office construction supervision, and plant start-up). Subcontracts The total cost of subcontracted work. This cost item is normally zero in Aspen Process Economic Analyzer. G and A Overheads General and administrative costs associated with engineering, materials, and construction work. Contract Fee The total cost of contract fees for engineering, material, construction, any subcontracted work. Escalation The total capital costs escalation amount. This cost item is normally zero in Aspen Process Economic Analyzer. Contingencies The additional costs required to bring this project to completion. In Aspen Process Economic Analyzer, this cost item is automatically calculated based on the project type and process complexity. Total Project Cost The total project capital cost of the plant calculated by the Icarus Evaluation Engine as of the “System Cost Base Date”. Adjusted Total Capital Cost Indicates the Total Project Cost (described above) adjusted to the Start of Basic Engineering. The Total Project Cost is escalated , using the Project Capital Escalation Parameter, from the system Cost Base date to the start date of basic engineering. Below is the formula used: C_at=C_t*(1+(t_diff*e)/(w*7*100)) where: C_at = Adjusted Total Capital Cost C_t = Total Capital Cost t_diff = Time difference between System Cost Base Date and Start Date for Engineering e = Project Capital Escalation w = Number of weeks per period Raw Material Costs and Product Sales Raw Materials Cost per Hour 11 Evaluating the Project Total raw material usage cost per hour specified in the Raw Material Specifications file. 446 Total Raw Materials Cost Total cost of raw materials per period. This number is generated by multiplying Raw Materials Cost per Hour by Operating Hours per Period. Products Sales per Hour Total produced product sales expressed in cost per hour. Total Products Sales Total product sales per period. This number is generated by multiplying Products Sales per Hour by Operating Hours per Period. Main Product Name The main product of the plant is considered to be the product which produces the largest sales figure per period. This field contains the description of the main product (assigned by the user). Main Product Rate The production rate of the main product. Main Product Unit Cost The unit cost rate of the main product. Main Product The production basis (or unit of measure) of Production Basis the main product (LB, GALLONS, etc.). Main Product Rate per Period The production rate of the main product per period . Main Product Sales The total sales figure of the main product per period. By-product Sales The total sales figure per period of the by-products (i.e., products other than the main product of the plant). Operating Labor and Maintenance Costs Operating Labor Operators per Shift The number of operators per shift per hour necessary to operate the plant. Unit Cost The wage rate for each operator expressed in cost per operator per shift. Total Operating Labor Cost Total operating labor cost obtained by multiplying number of operators per shift by the unit cost and by Operating Hours per Period. Maintenance Cost/8000 Hours The cost of maintaining the facility equipment for 8000 hours of operation of the facility. Total Maintenance Cost The total maintenance cost of the facility per period. Supervision Supervisors per Shift 11 Evaluating the Project The number of supervisors per shift per hour necessary to oversee personnel who operate the facility. 447 Unit Cost The wage rate for each supervisor expressed in cost per supervisors per shift. Total Supervision Cost Total supervising labor cost obtained by multiplying number of supervisors per shift by the unit cost and by Operating Hours per Period. Utilities Costs The utility cost breakdown is given below for electricity, potable water, fuel and instrument air as well as user defined process utilities such as steam. Note: The Process utilities details are available only when the results are viewed in Excel. These are made available through separate spreadsheets. The description of each utility includes: Rate The rate of use of the utility in terms of amount per hour. Unit Cost The unit cost of the utility in cost per amount. Total Cost The total cost of the utility in cost per period. Cashflow Cashflow (CASHFLOW.ICS) calculates the net present value (NPV), internal rate of return (IRR), profitability index (PI), payback period, etc. The spreadsheet displays the cashflow information shown by period. The beginning part of the spreadsheet contains data/results carried over from the Project Summary (PROJSUM.ICS) spreadsheet. Item 11 Evaluating the Project Description 448 TW Number of Weeks per Period T Number of Periods for Analysis DTEPC Duration of EPC Phase DT Duration of EPC Phase and Startup WORKP Working Capital Percentage OPCHG Operating Charges PLANTOVH Plant Overhead CAPT Total Project Cost RAWT Total Raw Material Cost PRODT Total Product Sales OPMT Total Operating Labor and Maintenance Cost UTILT Total Utilities Cost ROR Desired Rate of Return/Interest Rate AF ROR Annuity Factor TAXR Tax Rate IF ROR Interest Factor ECONLIFE Economic Life of Project SALVAL Salvage Value (Percent of Initial Capital Cost) DEPMETH Depreciation Method DEPMETHN Depreciation Method Id ESCAP Project Capital Escalation ESPROD Products Escalation ESRAW ESLAB Raw Material Escalation Operating and Maintenance Labor Escalation ESUT Utilities Escalation START Start Period for Plant Startup PODE Desired Payout Period (excluding EPC and Startup Phases). Reserved for future use. POD Desired Payout Period: Reserved for future use. DESRET Desired Return on Project for Sales Forecasting. Reserved for future use. END End Period for Economic Life of Project GA G and A Expenses DTEP Duration of EP Phase before Start of OP Total Operating Labor Cost MT Total Maintenance Cost Construction Sales A number will appear in this category only after the time allotted for all prior phases (engineering, procurement, construction and startup phases) has expired. SP (Products Sales) 11 Evaluating the Project The total products sales value per period calculated in PROJSUM.ICS. 449 SPF (Forecasted Reserved for future use. Sales Annuity Factor) SF (Forecasted Sales) Reserved for future use. S (Total Sales) Indicates the amount received per period from sold products. This number is either SP or SF. Expenses Includes both capital and operating expenditures per period listed below. CAP (Capital Costs) Indicates, by period, total funds spent prior to startup. Unescalated Cumulative Capital Cost: Indicates the total capital costs spent through the current period. This is based on the Total Project Capital Cost in PROJSUM.ICS. Capital Cost: Indicates, by period, the amount of initial, non-variable costs associated with the project. This number is based on the Total Project Capital Cost found in PROJSUM.ICS. Cumulative Capital Cost: Indicates capital expenditures through period n. For example, the number in period 4 represents the total capital expenditures beginning in period 1 and ending in period 4. Working: Indicates the amount required to operate the facility before the revenue from product sales is sufficient to cover costs. Working Capital is a lumpsum amount which takes effect during the start-up period. It is escalated at rate equal to the Project Capital Escalation rate. OP (Operating Indicates, by period, the total expenditure on the Costs) following items necessary to keep the facility operating: Raw Materials, Operating Labor Cost, Maintenance Cost, Utilities, Operating Charges, Plant Overhead, Subtotal Operating Costs, and G and A Costs. This number is the Total Operating Cost imported from PROJSUM.ICS and entered in this field after capital expenditures cease. (R)Revenue Indicates, by period, the amount of money available after capital and operating expenses have been paid. This number is obtained by subtracting Capital Costs and Operating Costs from Sales. DEP Depreciation Expense: the amount by which the value of the capital cost decreases each period. The Total Project Capital Cost is depreciated, via the chosen depreciation method, over the useful Economic Life of the facility. The Straight Line Method assumes that the item will depreciate by a constant amount over its Economic life. When the Sum of the Years Method is used, the depreciation expense decreases during each year of the project’s useful life. When the Double Declining Balance Method is used, the project is depreciated in geometric increments. The Accelerated Cost Recovery System 11 Evaluating the Project 450 assumes that the project begins operating in the second half of the first year, rather than in the beginning of the first year. E Earnings Before Taxes: funds available after all expenses have been paid. This number is obtained by subtracting the Depreciation and the Interest Expenses from the Revenue. TAX Indicates amount owed to the government. This number is obtained by multiplying the tax rate by Earnings Before Taxes. NE Net Earnings: funds available after taxes have been paid. This number is obtained by subtracting the Taxes from the Earnings Before Taxes. TED Total Earnings: total cash available from project. This number is computed by adding the Depreciation Expense to the Net Earnings. Since the depreciation expense is a non-cash expense (no cash actually leaves the facility in order to pay the depreciation expense) adding the depreciation to the net earnings gives the total cash flow obtained from the project. Inclusion of the Depreciation Expenses reduces the amount of taxable income. TEX Total Expenses (Excludes Taxes and Depreciation): the total expenses of the project including capital, operating, and any interest expense. FVI Future Value of Cumulative Cash Inflows: sums the Sales received through period n and indicates what the Sales would be if they had been received in the current period. For example, the value in period 4 is what the sales in periods 1-4 would have been if all of these funds had been received in period 4. PVI Present Value of Cumulative Cash Inflows: the current worth of all the cash received through period n. For example, the number in period 4 represents the value that the sales generated in periods 1 through 4 would be if those sales were received in the first period. This number is obtained by summing all of sales from prior time periods adding this amount to sales in the current time period. Using the specified interest rate, this total is then discounted back to the first time period. PVOS Present Value of Cumulative Cash Outflows, Sales. PVOP Present Value of Cumulative Cash Outflows, Products: the current worth of all of the cash paid through period n. For example, the number in period 4 represents the value that the expenses paid in periods 1 through 4 would be if those expenses were paid in the first period. This number is obtained by summing all of the outflows (Capital Costs, Operating Costs, Interest Expense) from prior time periods and adding this amount to the outflows in the current period. Using the specified interest rate, this total is then discounted back to the first time period . PVO Present Value of Cumulative Cashflows: represents PVOS or PVOP depending on whether or not you entered a desired payout period. If you entered a desired payout period, the basis for the cash outflow calculation is the Forecasted Sales. Otherwise, the basis is Product Sales. PV Present Value of Cashflows: the present worth of the Total Earnings received in the current period. For example, the number in period 4 represents the value that the Total Earnings generated in period 4 discounted back to the first time period. Final results are shown below: 11 Evaluating the Project 451 NPV Net Present Value: the current worth of all the Net Earnings received through period n. For example, the number in period 4 represents the value that the Net Earnings generated in periods 1 through 4 if those earnings were received in the first period. This number is obtained by summing all of the Net Earnings from prior time periods and adding this amount to the Net Earnings in the current time period. Using the specified interest rate, this total is then discounted back to the first time period. The sign of this value determines the analysis result. If, in a certain period, the sign of the net present value is negative, then the proposed investment appears not to be profitable, thus far. For example, if the sign of the net preset value is negative in period 3, then the project does not appear to be profitable during periods 1, 2, and 3. However, if the sign is positive, then the project appears to be profitable, from period 3 onward. If the net present value equals zero, then the project does not incur any losses or gains (break-even point). IRR Internal Rate of Return: the rate at which the present value of all cash flows is zero. It is also known as the Discounted Cash-Flow Rate of Return. This value is calculated at the “End Period for Economic Life of Project” (i.e., “Economic Life of Project” and considering the length of EPC and Startup Period). At the “End Period for Economic Life of Project”, it is assumed the salvage value of the plant and the working capital are recouped. IRR is the after-tax interest rate at which the organization can borrow funds and break even at the end of the project life. MIRR Modified Internal Rate of Return: the profitability of the project. The internal rate of return is the interest rate which equates the present value of a project’s expected cash inflows to the present value of the project’s expected costs (or outflows). The internal rate of return for each period is calculated by dividing the Present Value of Cumulative Inflows by the Present Value of Cumulative Outflows and raising this to a power and multiplied by 100. Two criteria are critical in evaluating the internal rate of return. First, if the sign of the rate of return is negative, the project appears not to be profitable. If the sign is positive, then the project appears to be profitable. If the rate of return equals zero then the project incurs no losses or gains (break-even point). In addition, if the rate of return is greater than the rate which could be obtained from other opportunities (i.e., investing in a bank), then the project probably should be undertaken. NRR Net Rate of Return: the profitability of the project. The net rate of return for each period is calculated by dividing the Net Present Value by the Present Value of Cumulative Outflows and then multiplying the result by 100. PO Payout Period: the expected number of years required to recover the original investment in the project. This row will indicate the length of time that the facility needs to operate in order to recover the initial capital investment (total capital cost plus working capital). If a number is entered for the Desired Payout Period, the spreadsheet will determine the amount of Sales necessary to meet this desired payout. ARR Accounting Rate of Return: measures a project’s contribution to the firm’s net income. This number is the ratio of the project’s Average Annual Expected Net Income to its Average Investment. For example, the Average Annual Expected Net Income for the fourth period is determined by summing net earnings from periods 1 through 4 and divided by 4. The Average Investment is determined by finding the Salvage Value, and adding this 11 Evaluating the Project 452 number to the Total Project Cost and dividing this total by 2. If the accounting rate of return is greater than one, then this is an indication that the project might be a profitable undertaking. If the sign is negative, then the project does not appear to be profitable. If this number equals zero then the project incurs no losses or gains (break-even point). PI Profitability Index: shows the relative profitability of any project; it shows the present value of the benefits relative to the present value of the costs. For each period, this number is computed by dividing the Present Value of the Cumulative Cash Inflows by the Present Value of the Cumulative Cash Outflows. If the profitability index is greater than one, then the project appears to be profitable. If this index is less than one, then the project appears not to be profitable. If this number equals zero then the project incurs no losses or gains (break-even point). Analysis Analysis results are shown by period. “( - )” indicates the project in the current period appears unprofitable, while “0” indicates break-even status. Depreciation Calculations This section presents details on the calculation of depreciation. Executive Summary Executive Summary (EXECSUM.ICS) contains a project summary intended to be reviewed by executives and other business decision makers. It contains the following information: PROJECT NAME 11 Evaluating the Project Aspen Process Economic Analyzer project name 453 CAPACITY Capacity of plant for major product PLANT LOCATION Location of plant BRIEF DESCRIPTION Brief description of project, from Project Properties SCHEDULE Start Date for Engineering The beginning date for EPC (engineering, procurement, and construction) Duration of EPC Phase The calculated EPC duration in weeks Completion Date for Construction The calendar date for the end of EPC Length of Start-up Period Number of weeks scheduled for start-up beyond the end of the EPC phase INVESTMENT Currency Conversion Conversion factor between user-selected currency to the currency used by the system internally for the selected Country basis. For example, if the US country basis is selected, the internal system currency is US Dollars. Therefore, all numbers will be reported in US Dollars. However, if a currency conversion rate of 1.5 is specified, all internal values will be multiplied by 1.5 and then reported Total Project Capital The total capital cost investment needed for the project. If the calculated EPC period is more than a year, the capital costs expenditure will be spread out over the length of the EPC period Total Operating Cost The total of raw material, utility, operating labor, maintenance, operating charges, plant overhead and G and A expenses Total Raw Materials Cost The total raw material cost of the facility expressed in terms of cost per year Total Utilities Cost The total utilities usage cost expressed in terms of cost per year Total Product Sales The total product sales of the facility expressed in terms of cost per year Desired Rate of Return Desired rate of return expressed in terms of percent per year. PROJECT INFORMATION Simulator Type The name of the process simulator from which process data was imported Version The version of the process simulator Report File The file name of the process simulator report file Report Date Date and time of the process simulator report file 11 Evaluating the Project 454 Economic Analysis Type The name of the Icarus system used for the evaluation Version Version number of the Icarus system. System Cost Base Date The capital costs basis date of the system. The Adjusted Total Project Cost represents the calculated capital cost of the project (calculated at this base date) escalated to the Start Date of Engineering. Project Directory Directory path for the current Aspen Process Economic Analyzer project Analysis Date Date investment analysis was run. Country basis Country basis for the capital costs/schedule analysis Project Type Project type identified in the standard basis specs Design code Selected design code for equipment Prepared By Identifier for the preparer of the process evaluator Using the Reporting Assistant The Reporting Assistant feature lets you create your own customized report spreadsheets, combining information from all other Icarus generated spreadsheets. The sections below describe the steps to create such custom reports when viewing the results within the Icarus Main Window (ICS) and when viewing them in Excel. Using the Reporting Assistant in ICS To develop a customized spreadsheet file and template 1 On the Tools menu, click Options | Reporting Assistant. 11 Evaluating the Project 455 The Reporting Assistant Options dialog box appears. 2 On the Report File tab, click New. 3 In the Save As dialog box, type a name for the report file that will contain your customized spreadsheet. For example, type Custom as shown below. 4 Click Save. 5 Click the Report Templates tab. 11 Evaluating the Project 456 6 In the Template Files section, click New. 7 In the Save As dialog box, type a name for the template file (for example, summary) and click Save. This example creates a reporting template for future use called Summary.tra. 8 In the Template Entries section, click New Entry. In the Column Label field, enter a label (for example, “Project Name”) for the first column on your custom report spreadsheet. The Display Column box should automatically display “1”. 9 The Entry Definition section defines the data to be entered in the above column. Select a file name in the Source box, then enter the column and row of the source data. For example, in the figure below, the contents of Column C, Row 8 of Project.ics has been specified to appear in the customized report spreadsheet’s Project Name column. 11 Evaluating the Project 457 10 Follow the same procedure (steps 7 - 8) to add more entries. You can use a variety of sources. For example, adding the following entries will result in a report template that uses all three of the previously discussed .ics files as sources. Column Label Display Column Source Source Column Source Row Project Name 1 projsum.ics C 8 Start Date for Engineering 2 projsum.ics C 61 Tax Rate 3 projsum.ics C 112 Purchased Equipment Cost 4 projsum.ics C 172 Total Project Cost 5 cashflow.ics C 14 Total Maintenance Cost 6 cashflow.ics C 40 Completion Date for Construction 7 execsum.ics B 17 11 When all the template entries are added, return to the Report File tab view. To the right of the Template File field, click Browse. 12 Select the newly created template file (for example, Summary.tra) and click Open. 13 Click OK to exit the Reporting Assistant Options dialog box. Using the Reporting Assistant in Excel mode When the results are viewed in Excel, certain additional results are made available to the user. These include details about the process utilities as well as the individual raw material and products in the project. 11 Evaluating the Project 458 The Excel mode uses two files: Aspen Process Economic AnalyzerWB.xls This workbook contains the spreadsheets used to report the investment analysis results. This is an ICARUS system file and users are recommended not to modify its contents. Aspen Process Economic AnalyzerWB_TRA.xls The Aspen Process Economic AnalyzerWB_TRA.xls file stores the customizations that are in turn used by the Aspen Process Economic AnalyzerWB.xls. You can modify its contents to customize the Run Summary worksheet. The global copy of these files resides in the \Data\ICS folder. The files are copied into the individual project folder when the investment analysis results are invoked Note: If copies of these files already exist within the projects, then they may not be replaced and so may have to be replaced manually by the user. In the case of ICARUS projects that are migrated from previous versions, any older versions of these files will be saved as a backup and the newer versions will be used. The Run Summary worksheet in the Aspen Process Economic AnalyzerWB.xls workbook is the sheet that can be customized by the user. The Aspen Process Economic AnalyzerWB_TRA.xls file stores the customizations that are in turn used by the Aspen Process Economic AnalyzerWB.xls. The Aspen Process Economic AnalyzerWB_TRA.xls files stores: • The template to be used in the Run Summary worksheet • Any additional user defined functions (UDF) that the user wishes to incorporate. The default Aspen Process Economic AnalyzerWB_TRA.xls that is provided with the system can be used to review these aspects of the file. The sections below explain this further. Steps to customize the Run Summary worksheet: If you want to view a particular piece of information from one of the spreadsheets in Aspen Process Economic AnalyzerWB.xls, on the Run Summary sheet, follow these steps. 1 Close any open ICARUS projects and close ICARUS. 2 Open the ICS>>Aspen Process Economic AnalyzerWB_TRA.xls file. 3 Edit the Template worksheet and add any user-defined functions that you intend to use (see sections below). 4 Save and close the Aspen Process Economic AnalyzerWB_TRA.xls file. 5 Re-open the ICARUS project. 11 Evaluating the Project 459 6 Delete or rename any previous versions of Aspen Process Economic AnalyzerWB.xls and Aspen Process Economic AnalyzerWB_TRA.xls that may exist within the ic_cache>>Current Working Project folder. 7 Run the investment analysis and ensure that your changes are reflected in the Run Summary worksheet. Aspen Process Economic AnalyzerWB_TRA.xls>>Template worksheet: The Template worksheet has three columns that you can modify. This column denotes Dest the destination column in the Run Summary worksheet, where a particular piece of data should be reported. Column Heading the title that should be used. Source/Formula the source from which the data should be retrieved. Formulas could also be used. Here is an example: Dest Column Heading Source/Formula C Time Now() D Project Name 'Project Summary'!C8 Keep the following in mind when editing the Template: • Entries must begin at cell D10 • Processing of entries will end when a cell in column D is empty • The Source/Formula should not contain “=”; Now(),'Project Summary'!C8 • If you intend to define and use other functions, see the sections below. for example, Aspen Process Economic AnalyzerWB_TRA.xls>>User defined functions: All user-defined functions should begin with UDF_, 11 Evaluating the Project 460 for example, UDF_UtilCost_Steam100PSI(). Functions that begin with Aspen Process Economic AnalyzerF_ refer to Aspen Process Economic Analyzer system functions. Using the Visual Basic Editor, you can view, edit, and add user defined functions in the Aspen Process Economic AnalyzerWB_TRA.xls workbook. The screen capture below shows a snippet from this file. Using the samples provided, you could add more functions in the sections marked Insert your functions here. If you need technical assistance in this regard, contact the AspenTech Support Team. Generating the Custom Report To generate a report developed in Reporting Assistant: 1 Run a project evaluation. 2 On the Run menu, click Add Entry for Reporting Assistant. Aspen Process Economic Analyzer generates the report based upon the template created in the Reporting Assistant. The data that was entered under List of Entries on the Reporting Assistant Options dialog box appears as columns in the spreadsheet. Every time Add Entry for Reporting Assistant is selected, the latest data is entered on the bottom row of the report. This way, you can compare results. 11 Evaluating the Project 461 Item Evaluation Aspen Process Economic Analyzer allows you to run an evaluation on a single component and view an Item Report. The type of Item Report displayed can be selected in Preferences (see page 48). X519H X To run an item evaluation and display the Item Report: 1 Right-click on the component in either Project Explorer or the List view, and then click Evaluate Item on the pop-up menu. Aspen Process Economic Analyzer runs the item evaluation. Note: If the evaluation has already been run, you only have to click Item Report. 2 Right-click on the component and click Item Report on the pop-up menu. You can also click the Evaluate button on the Component Specifications form to run the item evaluation and display the Item Report. Aspen Process Economic Analyzer displays the Item Report. 11 Evaluating the Project 462 3 You can include multiple components in the Item Report: on the List view (area level), select the desired components, right-click on one of the components, and click Item Report on the pop-up window. The resulting Item Report lists individually the summary data (cost or sizing) for each selected component. Automatic Item Evaluation You can have Aspen Process Economic Analyzer automatically run an item evaluation whenever you click OK or Apply on a Component Specifications form. To turn automatic item evaluation on and off: 1 On the Tools menu, point to Options. 2 On the Options sub-menu, a check appears next to Automatic Item Evaluation when the feature is turned on. Clicking Automatic Item Evaluation turns the feature on and off. 11 Evaluating the Project 463 11 Evaluating the Project 464 Appendix A: Equipment and Slots of those Equipment Affected by Mapping The following table lists the Equipment and Slots of those Equipment which will be affected by mapping: Important: When you do Map Based On Last Session, the slots listed on this table WILL CHANGE. Object Name Attributes wiped out during re-size DAT MIXER CpTangentTangentHeight CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER VESSEL T-T HEIGHT DAT OPEN TOP CpTangentTangentHeight CpVesselDiameter CpDesignTemperature CpLiquidVolume DESIGN TEMPERATURE CAPACITY DIAMETER VESSEL T-T HEIGHT DAT REACTOR CpTangentTangentHeight CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DCP ANSI CpPumpEfficiencyPercent Appendix A: Equipment and Slots of those Equipment Affected by Mapping 465 CpFluidSpecificGravity CpFluidHead CpDriverPower CpDesignTemperature CpDesignGaugePressure CpLiquidFlowrate Capacity Head Liquid specif. grav. Driver power Design temperature Design press. -gauge Pump fractional efficiency Pump % efficiency No. of identical items DCP ANSI PLAST No. of identical items Pump % efficiency Pump fractional efficiency Design press. -gauge Design temperature Driver power Liquid specif. grav. Head Capacity CpLiquidFlowrate CpDesignGaugePressure CpDesignTemperature CpDriverPower CpFluidHead CpFluidSpecificGravity CpPumpEfficiencyPercent DCP API 610 CpPumpEfficiencyPercent CpFluidSpecificGravity CpFluidHead CpDriverPower CpDesignTemperature CpDesignGaugePressure CpLiquidFlowrate Capacity Head Liquid specif. grav. Driver power Design temperature Design press. -gauge Pump fractional efficiency Pump % efficiency Appendix A: Equipment and Slots of those Equipment Affected by Mapping 466 No. of identical items DCP API 610 IL CpPumpEfficiencyPercent CpFluidSpecificGravity CpFluidHead CpDriverPower CpDesignTemperature CpDesignGaugePressure CpLiquidFlowrate Capacity Head Liquid specif. grav. Driver power Design temperature Design press. -gauge Pump fractional efficiency Pump % efficiency No. of identical items DCP CENTRIF CpPumpEfficiencyPercent CpFluidSpecificGravity CpFluidHead CpDriverPower CpDesignTemperature CpDesignGaugePressure CpLiquidFlowrate Capacity Head Liquid specif. grav. Driver power Design temperature Design press. -gauge Pump fractional efficiency Pump % efficiency No. of identical items DCP GEN SERV No. of identical items Pump % efficiency Pump fractional efficiency Design press. -gauge Design temperature Driver power Liquid specif. grav. Head Capacity CpLiquidFlowrate CpDesignGaugePressure CpDesignTemperature CpDriverPower Appendix A: Equipment and Slots of those Equipment Affected by Mapping 467 CpFluidHead CpFluidSpecificGravity CpPumpEfficiencyPercent DCP GEN-SERV CpPumpEfficiencyPercent CpFluidSpecificGravity CpFluidHead CpDriverPower CpDesignTemperature CpDesignGaugePressure CpLiquidFlowrate Capacity Head Liquid specif. grav. Driver power Design temperature Design press. -gauge Pump fractional efficiency Pump % efficiency No. of identical items DCP IN LINE CpPumpEfficiencyPercent CpFluidSpecificGravity CpFluidHead CpDriverPower CpDesignTemperature CpDesignGaugePressure CpLiquidFlowrate Capacity Head Liquid specif. grav. Driver power Design temperature Design press. -gauge Pump fractional efficiency Pump % efficiency No. of identical items DDDTPACKED CpTrayType CpTangentTangentHeightTopSection CpDiameterTopSection CpDesignTemperatureTopSection CpDesignPressureTopSection CpTangentTangentHeightBottomSection CpDiameterBottomSection CpDesignTemperatureBottomSection CpDesignPressureBottomSection TRAY TYPE BOTTOM DESIGN PRESS. Appendix A: Equipment and Slots of those Equipment Affected by Mapping 468 BOTTOM DESIGN TEMP. TOP DESIGN PRESSURE TOP DESIGN TEMP. TOP T-T HEIGHT TOP SECT'N DIAMETER BOTTOM T-T HEIGHT BOTTOM SECTION DIAM. DDDTTRAYED CpTrayType CpTangentTangentHeightTopSection CpDiameterTopSection CpDesignTemperatureTopSection CpDesignPressureTopSection CpTangentTangentHeightBottomSection CpDiameterBottomSection CpDesignTemperatureBottomSection CpDesignPressureBottomSection TRAY TYPE BOTTOM DESIGN PRESS. BOTTOM DESIGN TEMP. TOP DESIGN PRESSURE TOP DESIGN TEMP. TOP T-T HEIGHT TOP SECT'N DIAMETER BOTTOM T-T HEIGHT BOTTOM SECTION DIAM. DF ROTY DISK CpSurfaceArea SURFACE AREA No. of identical items DF ROTY DRUM CpSurfaceArea SURFACE AREA No. of identical items DGC CENTRIF CpDesignTemperatureInlet CpDesignGaugePressureInlet CpDesignGaugePressureOutlet CpActualGasFlowrateInlet ACTUAL CAPACITY INLET PRESSURE-GAUGE EXIT PRESSURE -GAUGE INLET TEMPERATURE No. of identical items DGC CENTRIF IG No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY EXIT TEMPERATURE Appendix A: Equipment and Slots of those Equipment Affected by Mapping 469 CpActualGasFlowrateInlet CpDesignGaugePressureOutlet CpDesignTemperatureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet DGC RECIP MOTR No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY CpActualGasFlowrateInlet CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet DHE AIR COOLER DUTY [2]CpTubeWallThicknessSecondService [3] CpTubeWallThicknessThirdService CpTubeWallThicknessFirstService CpTubeLength CpNumberBays CpNumberTubeRows [3] CpDesignTemperatureInletThirdService [2] CpDesignTemperatureInletSecondServ CpDesignTemperatureInletFirstService CpHeight [3] CpDesignGaugePressureThirdService [2] CpDesignGaugePressureSecondService CpDesignGaugePressureFirstService CpBayWidth [2] CpBareTubeAreaSecondService [3] CpBareTubeAreaThirdService CpBareTubeAreaFirstService No. of tube rows Height Number of bays Bay width Tube length Tube thickness/BWG Inlet temperature Design press. -gauge Bare tuo. of identical items DHE FIXED T S No. of identical items Surface area Number of shells Tube pressure -gauge Tube temperature Appendix A: Equipment and Slots of those Equipment Affected by Mapping 470 Shell pressure-gauge Shell temperature No. of tubes/shell Extended tube length Tube thickness Tube pitch No. of tube passes Tube outside diam. Shell diameter CpTubeLengthExtended CpNumberTubePasses CpNumberTubesPerShell CpNumberShells CpShellDiameter CpDesignGaugePressureShell CpDesignTemperatureShell CpHeatTransferArea CpTubeOutsideDiameter CpTubePitch CpTubeDesignGaugePressure CpDesignTemperatureTube CpTubeWallThickness Required surface area (with overdesign) RAW SURFACE AREA DUTY DHE FLOAT HEAD No. of identical items Surface area Number of shells Tube pressure -gauge Tube temperature Shell pressure-gauge Shell temperature No. of tubes/shell Extended tube length Tube thickness Tube pitch No. of tube passes Tube outside diam. Shell diameter CpTubeLengthExtended CpNumberTubePasses CpNumberTubesPerShell CpNumberShells CpShellDiameter CpDesignGaugePressureShell CpDesignTemperatureShell Appendix A: Equipment and Slots of those Equipment Affected by Mapping 471 CpHeatTransferArea CpTubeOutsideDiameter CpTubePitch CpTubeDesignGaugePressure CpDesignTemperatureTube CpTubeWallThickness Required surface area (with overdesign) RAW SURFACE AREA DUTY DHE PRE ENGR No. of identical items Surface area Tube pressure -gauge Tube temperature Shell pressure-gauge Shell temperature Tube thickness No. of tube passes CpNumberTubePasses CpDesignGaugePressureShell CpDesignTemperatureShell CpHeatTransferArea CpTubeDesignGaugePressure CpDesignTemperatureTube CpTubeWallThickness Required surface area (with overdesign) RAW SURFACE AREA DUTY DHE TEMA EXCH DUTY RAW SURFACE AREA Required surface area (with overdesign) CpTubeWallThickness CpDesignTemperatureTube CpTubeDesignGaugePressure CpTubePitch CpTubeOutsideDiameter CpHeatTransferArea CpDesignTemperatureShell CpDesignGaugePressureShell CpShellDiameter CpNumberShells CpNumberTubesPerShell CpNumberTubePasses CpTubeLengthExtended Shell diameter Tube outside diam. No. of tube passes Appendix A: Equipment and Slots of those Equipment Affected by Mapping 472 Tube pitch Tube thickness Extended tube length No. of tubes/shell Shell temperature Shell pressure-gauge Tube temperature Tube pressure -gauge Number of shells Surface area No. of identical items DHE U TUBE No. of identical items Surface area Number of shells Tube pressure -gauge Tube temperature Shell pressure-gauge Shell temperature No. of tubes/shell Extended tube length Tube thickness Tube pitch No. of tube passes Tube outside diam. Shell diameter CpTubeLengthExtended CpNumberTubePasses CpNumberTubesPerShell CpNumberShells CpShellDiameter CpDesignGaugePressureShell CpDesignTemperatureShell CpHeatTransferArea CpTubeOutsideDiameter CpTubePitch CpTubeDesignGaugePressure CpDesignTemperatureTube CpTubeWallThickness Required surface area (with overdesign) RAW SURFACE AREA DUTY DHT HORIZ DRUM VESSEL T-T LENGTH DIAMETER CAPACITY DESIGN TEMPERATURE DESIGN PRESS. -GAUGE Appendix A: Equipment and Slots of those Equipment Affected by Mapping 473 CpLiquidVolume CpDesignGaugePressure CpDesignTemperature CpVesselDiameter CpTangentTangentLength DHT JACKETED CpTangentTangentLength CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER VESSEL T-T LENGTH DHT MULTI WALL CpTangentTangentLength CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER VESSEL T-T LENGTH DRB KETTLE RAW SURFACE AREA Required surface area (with overdesign) CpDesignTemperatureTube CpTubeDesignGaugePressure CpHeatTransferArea CpDesignTemperatureShell CpDesignGaugePressureShell CpDuty SHELL PRESSURE-GAUGE TUBE PRESSURE -GAUGE SHELL TEMPERATURE TUBE TEMPERATURE DUTY NO. OF IDENTICAL ITEMS surface area DRB THERMOSIPH RAW SURFACE AREA Required surface area (with overdesign) CpDesignTemperatureTube CpTubeDesignGaugePressure CpHeatTransferArea CpDesignTemperatureShell Appendix A: Equipment and Slots of those Equipment Affected by Mapping 474 CpDesignGaugePressureShell CpDuty SHELL PRESSURE-GAUGE TUBE PRESSURE -GAUGE SHELL TEMPERATURE TUBE TEMPERATURE DUTY NO. OF IDENTICAL ITEMS surface area DRB U TUBE surface area NO. OF IDENTICAL ITEMS DUTY TUBE TEMPERATURE SHELL TEMPERATURE TUBE PRESSURE -GAUGE SHELL PRESSURE-GAUGE CpDuty CpDesignGaugePressureShell CpDesignTemperatureShell CpHeatTransferArea CpTubeDesignGaugePressure CpDesignTemperatureTube Required surface area (with overdesign) RAW SURFACE AREA DTW DC HE TW CpDesignGaugePressure CpDesignTemperature CpVesselDiameter CpTangentTangentHeight DESIGN PRESS. -GAUGE DESIGN TEMPERATURE Diameter Vessel t-t height DTW PACKED CpTangentTangentHeight CpTrayType CpTotalPackingHeight CpVesselDiameter CpDesignTemperature CpDesignGaugePressure DESIGN PRESS. -GAUGE DESIGN TEMPERATURE TRAY TYPE Diameter Vessel t-t height Total packing height DTW TRAYED CpTangentTangentHeight CpTrayType Appendix A: Equipment and Slots of those Equipment Affected by Mapping 475 CpTraySpacing CpNumberTrays CpVesselDiameter CpDesignTemperature CpDesignGaugePressure DESIGN PRESS. -GAUGE DESIGN TEMPERATURE NUMBER OF TRAYS TRAY TYPE Diameter Vessel t-t height tray spacing DVT CONE BTM CpVesselHeight CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER HEIGHT DVT CYLINDER CpVesselDiameter CpTangentTangentHeight CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DVT GAS HOLDER CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpGasVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER DVT JACKETED CpTangentTangentHeight CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER VESSEL T-T HEIGHT DVT LIVE BTM CpVesselHeight Appendix A: Equipment and Slots of those Equipment Affected by Mapping 476 CpVesselDiameter CpDesignTemperature CpSolidVolume DESIGN TEMPERATURE CAPACITY DIAMETER HEIGHT DVT MULTI WALL CpTangentTangentHeight CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER VESSEL T-T HEIGHT DVT SPHERE CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER DVT SPHEROID CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolume DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER DVT STORAGE CpVesselHeight CpVesselDiameter CpDesignTemperature CpDesignGaugePressure CpLiquidVolumeGallonsBarrels DESIGN PRESS. -GAUGE DESIGN TEMPERATURE CAPACITY DIAMETER HEIGHT EAC CENTRIF M No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE Appendix A: Equipment and Slots of those Equipment Affected by Mapping 477 INLET PRESSURE-GAUGE ACTUAL CAPACITY CpActualGasFlowrate CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet EAC CENTRIF T No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY CpActualGasFlowrate CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet EAC RECIP GAS No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY DRIVER POWER CpActualGasFlowrate CpDriverPower CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet EAC RECIP MOTR No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY CpActualGasFlowrateInlet CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet EAC SINGLE 1 S No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY CpActualGasFlowrate CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet EAC SINGLE 2 S No. of identical items INLET TEMPERATURE Appendix A: Equipment and Slots of those Equipment Affected by Mapping 478 EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY CpActualGasFlowrate CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet EAD AIR DRYER CpGasFlowrate CAPACITY EAT COND CELL VOLUME CpCellVolume EAT FLOAT CELL VOLUME PER CELL NUMBER OF CELLS CpNumberCells CpVolumePerCell ECP AXIAL FLOW CpTemperature CpFluidSpecificGravity CpFluidHead CpDriverPower Head Liquid specif. grav. Driver power Temperature No. of identical items ECP TURBINE CpTemperature CpFluidSpecificGravity CpFluidHead CpDriverPower Head Liquid specif. grav. Driver power Temperature No. of identical items ECR BRADFORD CpCrusherFlowrate CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR CONE CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER Appendix A: Equipment and Slots of those Equipment Affected by Mapping 479 RATE ECR ECCENTRIC CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR GYRATOR CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR HAMMER MED RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER CpDriverPower CpMantleDiameter CpProductSize CpCrusherFlowrate ECR JAW CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR PULVERIZER CpFlowrate CpProductMeshSize CpProductFeedSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR REV HAMR RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER Appendix A: Equipment and Slots of those Equipment Affected by Mapping 480 CpMantleDiameter CpDriverPower CpProductSize CpCrusherFlowrate ECR ROLL RING CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR ROTARY CpProductSize CpMantleDiameter CpDriverPower CpCrusherFlowrate DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR S IMPACT RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER CpDriverPower CpMantleDiameter CpProductSize CpCrusherFlowrate ECR S ROLL HVY RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER CpCrusherFlowrate CpDriverPower CpMantleDiameter CpProductSize ECR S ROLL LT RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER CpDriverPower CpMantleDiameter CpProductSize CpCrusherFlowrate ECR S ROLL MED RATE MANTLE DIAMETER Appendix A: Equipment and Slots of those Equipment Affected by Mapping 481 PRODUCT SIZE DRIVER POWER CpDriverPower CpMantleDiameter CpProductSize CpCrusherFlowrate ECR SAWTOOTH CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE ECR SWING HAMR RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER CpDriverPower CpMantleDiameter CpProductSize CpCrusherFlowrate ECRYBATCH VAC CpLiquidVolume CAPACITY No. of identical items ECRYMECHANICAL CpLength LENGTH No. of identical items ECRYOSLO CpCrystallizerRate RATE No. of identical items ECT ATM SUSPEN CpDriverPower DRIVER POWER No. of identical items ECT BATCH AUTO No. of identical items DIAMETER CAPACITY CpCentrifugeCapacity [2] CpBatchFlowrate CpCentrifugeDiameter ECT BATCH BOTM No. of identical items DIAMETER CpCentrifugeDiameter ECT BATCH TOP No. of identical items DIAMETER CpCentrifugeDiameter Appendix A: Equipment and Slots of those Equipment Affected by Mapping 482 ECT BOT UNLOAD No. of identical items DIAMETER CpCentrifugeDiameter ECT DISK CpCentrifugeDiameter DIAMETER No. of identical items ECT INVERTING CpCentrifugeDiameter DIAMETER No. of identical items ECT RECIP CONV No. of identical items DIAMETER CpCentrifugeDiameter ECT SCREEN BWL No. of identical items DIAMETER INSIDE DIAMETER INSIDE LENGTH CpBowlDiameter CpBowlLength ECT SCROLL CON No. of identical items DIAMETER CpCentrifugeDiameter ECT SOLID BOWL CpBowlLength CpBowlDiameter DIAMETER INSIDE DIAMETER No. of identical items ECT TOP UNLOAD CpCentrifugeDiameter CpCentrifugeCapacity CAPACITY DIAMETER No. of identical items ECT TUBULAR CpBowlDiameter DIAMETER No. of identical items ECT VIBRATORY CpProductFeedSize CpScreenDiameter DIAMETER SCREEN DIAMETER No. of identical items ED ATMOS TRAY No. of identical items TRAY AREA CpTrayArea ED PAN CpSurfaceArea AREA No. of identical items Appendix A: Equipment and Slots of those Equipment Affected by Mapping 483 ED SPRAY CpEvaporationRate EVAPORATION RATE No. of identical items ED VAC TRAY No. of identical items TRAY AREA CpTrayArea EDC CENTRF PRE No. of identical items FLOW RATE CpGasFlowrate EDC CLOTH BAY CpSurfaceArea SURFACE AREA No. of identical items EDC CYCLONE CpCycloneDiameter DIAMETER No. of identical items EDC ELC H VOLT No. of identical items FLOW RATE CpGasFlowrate EDC ELC L VOLT No. of identical items FLOW RATE CpGasFlowrate EDC MULT CYCLO No. of identical items FLOW RATE CpGasFlowrate EDC PULSE SHKR CpGasFlowrate FLOW RATE No. of identical items EDC WASHERS SURFACE AREA No. of identical items EDD DOUBLE ATM CpTrayArea SURFACE AREA No. of identical items EDD SINGLE ATM CpTrayArea SURFACE AREA No. of identical items EDD SINGLE VAC CpTrayArea SURFACE AREA No. of identical items EE FALL FILM No. of identical items Heating area CpHeatTransferArea EE FORCED CIR CpHeatTransferArea Heating area No. of identical items EE LONG TUBE CpTubeMaterial Appendix A: Equipment and Slots of those Equipment Affected by Mapping 484 Mat'l of construction CpHeatTransferArea Tube material Heating area No. of identical items EE LONG VERT No. of identical items Area CpSurfaceArea EE STAND HOR No. of identical items Area CpSurfaceArea EE STAND VERT No. of identical items Area CpSurfaceArea EF CARTRIDGE CpLiquidFlowrate FLOW RATE No. of identical items EF LEAF DRY No. of identical items SURFACE AREA CpSurfaceArea EF LEAF WET No. of identical items SURFACE AREA CpSurfaceArea EF PLATE FRAM No. of identical items FRAME CAPACITY CpFrameCapacity EF SCROLL CpProductFeedSizeSelection FEED SIZE No. of identical items EF SEWAGE CpSurfaceArea SURFACE AREA No. of identical items EF SPARKLER CpSurfaceArea SURFACE AREA No. of identical items EF TUBULAR CpLiquidFlowrate FLOW RATE No. of identical items EF WHITEWATER CpLiquidFlowrate FLOW RATE No. of identical items EFU BOX CpStandardGasFlowrate CpProcessType CpDuty CpDesignTemperature Appendix A: Equipment and Slots of those Equipment Affected by Mapping 485 CpDesignGaugePressure No. of identical items Duty Standard gas flow Process type Design temperature Design press. -gauge EFU HEATER CpStandardGasFlowrate CpProcessType CpDuty CpDesignTemperature CpDesignGaugePressure No. of identical items Duty Standard gas flow Process type Design temperature Design press. -gauge EFU PYROLYSIS CpDesignGaugePressure CpDesignTemperature CpDuty CpProcessType CpStandardGasFlowrate No. of identical items Duty Standard gas flow Process type Design temperature Design press. -gauge EFU REFORMER CpStandardGasFlowrate CpProcessType CpDuty CpDesignTemperature CpDesignGaugePressure No. of identical items Duty Standard gas flow Process type Design temperature Design press. -gauge EFU VERTICAL CpDesignGaugePressure CpDesignTemperature CpDuty CpProcessType CpStandardGasFlowrate No. of identical items Appendix A: Equipment and Slots of those Equipment Affected by Mapping 486 Duty Standard gas flow Process type Design temperature Design press. -gauge EGC RECIP GAS No. of identical items INLET TEMPERATURE EXIT PRESSURE -GAUGE INLET PRESSURE-GAUGE ACTUAL CAPACITY DRIVER POWER CpActualGasFlowrate CpDriverPower CpDesignGaugePressureOutlet CpDesignGaugePressureInlet CpDesignTemperatureInlet EGP CANNED RTR CpLiquidFlowrate CpDriverPower Flow rate Driver power No. of identical items EGP GEAR CpLiquidFlowrate CpDriverPower Flow rate Driver power No. of identical items EGP MECH SEAL No. of identical items Driver power Flow rate CpLiquidFlowrate CpDriverPower EHE CROSS BORE RAW SURFACE AREA Required surface area (with overdesign) CpHeatTransferArea Heat transfer area No. of identical items EHE FIN TUBE RAW SURFACE AREA Required surface area (with overdesign) CpTubeLength CpNumberFins CpNumberTubesPerShell CpHeatTransferArea CpDesignGaugePressure Number of fins Design press. -gauge No. of tubes/shell Appendix A: Equipment and Slots of those Equipment Affected by Mapping 487 Tube length Heat transfer area No. of identical items EHE HEATER ELC No. of identical items Power output CpHeaterPower EHE HEATER STM No. of identical items Heat transfer area CpHeatTransferArea Required surface area (with overdesign) RAW SURFACE AREA EHE HEATER-ELC CpHeaterPower Power output No. of identical items EHE HEATER-STM RAW SURFACE AREA Required surface area (with overdesign) CpHeatTransferArea Heat transfer area No. of identical items EHE JACKETED RAW SURFACE AREA Required surface area (with overdesign) CpTubeLength CpNumberTubesPerShell CpHeatTransferArea CpDesignTemperature CpDesignGaugePressure Design temperature Design press. -gauge No. of tubes/shell Tube length Heat transfer area No. of identical items EHE ONE SCREW RAW SURFACE AREA Required surface area (with overdesign) CpHeatTransferArea Heat transfer area No. of identical items EHE PLAT FRAM DESIGN TEMPERATURE DESIGN PRESS. -GAUGE Surface area No. of identical items CpDesignGaugePressure CpDesignTemperature CpSurfaceArea CpHeatTransferArea Required surface area (with overdesign) Appendix A: Equipment and Slots of those Equipment Affected by Mapping 488 RAW SURFACE AREA EHE PLAT+FRAM RAW SURFACE AREA Required surface area (with overdesign) CpHeatTransferArea CpSurfaceArea CpDesignTemperature CpDesignGaugePressure No. of identical items Surface area DESIGN PRESS. -GAUGE DESIGN TEMPERATURE EHE SHELL TUBE No. of identical items Heat transfer area Tube length CpHeatTransferArea CpTubeLength Required surface area (with overdesign) RAW SURFACE AREA EHE SHELL+TUBE RAW SURFACE AREA Required surface area (with overdesign) CpTubeLength CpHeatTransferArea Tube length Heat transfer area No. of identical items EHE SPIRAL PLT RAW SURFACE AREA Required surface area (with overdesign) CpTubeDesignGaugePressure CpHeatTransferArea Tube pressure -gauge Heat transfer area No. of identical items EHE SUC HEATER No. of identical items Heat transfer area CpHeatTransferArea Required surface area (with overdesign) RAW SURFACE AREA EHE SUC-HEATER RAW SURFACE AREA Required surface area (with overdesign) CpHeatTransferArea Heat transfer area No. of identical items EHE TWO SCREW RAW SURFACE AREA Required surface area (with overdesign) CpHeatTransferArea Heat transfer area Appendix A: Equipment and Slots of those Equipment Affected by Mapping 489 No. of identical items EHE WASTE HEAT RAW SURFACE AREA Required surface area (with overdesign) CpFlowrate CpHeatTransferArea No. of identical items Rate Heat transfer rate EM ATTRITION CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE EM AUTOGENOUS CpSolidFlowrate CpProductSize CpDiameterInside CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE EM BALL MILL CpSolidFlowrate CpMantleDiameter CpProductSize CpDiameterInside CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE EM MIKRO PULV RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER CpDriverPower CpMantleDiameter CpProductSize CpCrusherFlowrate EM MIKRO-PULV CpCrusherFlowrate CpProductSize CpMantleDiameter CpDriverPower DRIVER POWER Appendix A: Equipment and Slots of those Equipment Affected by Mapping 490 PRODUCT SIZE MANTLE DIAMETER RATE EM ROD CHARGER RATE MANTLE DIAMETER PRODUCT SIZE DRIVER POWER CpDriverPower CpMantleDiameter CpRodDiameter CpProductSize CpSolidFlowrate EM ROD MILL CpSolidFlowrate CpProductSize CpDiameterInside CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE EM ROD-CHARGER CpSolidFlowrate CpProductSize CpRodDiameter CpMantleDiameter CpDriverPower DRIVER POWER PRODUCT SIZE MANTLE DIAMETER RATE EM ROLLER EP DIAPHRAGM CpTemperature CpFluidSpecificGravity CpFluidHead CpLiquidFlowrate CpDriverPower Liquid specif. grav. Head Temperature Flow rate Driver power No. of identical items EP DUPLEX CpTemperature CpFluidSpecificGravity CpFluidHead CpLiquidFlowrate Appendix A: Equipment and Slots of those Equipment Affected by Mapping 491 CpDriverPower Liquid specif. grav. Head Temperature Flow rate Driver power No. of identical items EP RECIP MOTR No. of identical items Driver power Flow rate Temperature Head Liquid specif. grav. CpDriverPower CpLiquidFlowrate CpFluidHead CpFluidSpecificGravity CpTemperature EP ROTARY CpTemperature CpFluidSpecificGravity CpFluidHead CpLiquidFlowrate CpDriverPower Liquid specif. grav. Head Temperature Flow rate Driver power No. of identical items EP SIMPLEX CpTemperature CpFluidSpecificGravity CpFluidHead CpLiquidFlowrate CpDriverPower Liquid specif. grav. Head Temperature Flow rate Driver power No. of identical items EP SLURRY CpTemperature CpFluidSpecificGravity CpFluidHead CpLiquidFlowrate CpDriverPower Liquid specif. grav. Appendix A: Equipment and Slots of those Equipment Affected by Mapping 492 Head Temperature Flow rate Driver power No. of identical items EP TRIPLEX CpTemperature CpFluidSpecificGravity CpFluidHead CpLiquidFlowrate CpDriverPower Liquid specif. grav. Head Temperature Flow rate Driver power No. of identical items ERD DIRECT CpSurfaceArea SURFACE AREA No. of identical items ERD INDIRECT CpSurfaceArea SURFACE AREA No. of identical items ERD JAC VACUUM No. of identical items CAPACITY CpDryerCapacity ERD JAC-VACUUM CpDryerCapacity CAPACITY No. of identical items ERD VACUUM CpDryerCapacity CAPACITY No. of identical items ETDSATM SYSTEM No. of identical items TRAY SURFACE CpTraySurfaceArea ETDSATM-SYSTEM CpTraySurfaceArea TRAY SURFACE No. of identical items ETDSTURBO CpTraySurfaceArea TRAY SURFACE No. of identical items ETDSVAC SYSTEM No. of identical items TRAY SURFACE CpTraySurfaceArea ETDSVAC-SYSTEM CpTraySurfaceArea TRAY SURFACE No. of identical items Appendix A: Equipment and Slots of those Equipment Affected by Mapping 493 ETDSVACUUM CpTraySurfaceArea TRAY SURFACE No. of identical items ETURCONDENSING CpPowerOutput Power output No. of identical items ETURGAS CpPowerOutput Power output No. of identical items ETURNON COND No. of identical items Power output CpPowerOutput ETURNON-COND CpPowerOutput Power output No. of identical items EVP MECH BOOST No. of identical items Actual capacity CpActualGasFlowrate EVP MECH-BOOST CpActualGasFlowrate Actual capacity No. of identical items EVP MECH-BOOST CpActualGasFlowrate Actual capacity No. of identical items EVP MECHANICAL CpDriverPower CpActualGasFlowrate Driver power Actual capacity No. of identical items EVP WATER SEAL No. of identical items Actual capacity CpActualGasFlowrate EVP WATER-SEAL CpActualGasFlowrate Actual capacity No. of identical items EVS HUMMER CpNumberDecks CpSurfaceArea NUMBER OF DECKS AREA No. of identical items EVS ONE DECK CpWidth CpLength WIDTH LENGTH No. of identical items Appendix A: Equipment and Slots of those Equipment Affected by Mapping 494 EVS SIFTER 1 No. of identical items DIAMETER CpScreenDiameter EVS SIFTER 2 No. of identical items DIAMETER CpScreenDiameter EVS SIFTER 3 No. of identical items DIAMETER CpScreenDiameter EVS SIFTER-1 CpScreenDiameter DIAMETER No. of identical items EVS SIFTER-2 CpScreenDiameter DIAMETER No. of identical items EVS SIFTER-3 CpScreenDiameter DIAMETER No. of identical items EVS THREE DECK CpWidth CpLength WIDTH LENGTH No. of identical items EVS TWO DECK CpLength CpWidth WIDTH LENGTH No. of identical items EVT PLAST TANK CpLiquidVolume CpTemperature CpVesselHeight CpDesignGaugePressure CpVesselDiameter GAUGE PRESSURE TEMPERATURE HEIGHT VOLUME DIAMETER EVT WOOD TANK CpLiquidVolume CpTemperature CpVesselHeight CpDesignGaugePressure CpVesselDiameter GAUGE PRESSURE TEMPERATURE HEIGHT Appendix A: Equipment and Slots of those Equipment Affected by Mapping 495 VOLUME DIAMETER EWFETHIN FILM Heat transfer area No. of identical items CpHeatTransferArea EWFEWFE SYSTEM Heat transfer area No. of identical items CpHeatTransferArea Size Interactive Slots - AirCooler Overall U Fin Thickness Duty CpTubePitch CpTubeOutsideDiameterFirstService CpTubeLength CpTubeFinHeight CpPowerPerFan CpNumberTubeRows CpNumberBays CpFinPitch CpBayWidth CpBareTubeAreaFirstService Overall Heat transfer Coefficient Size Interactive Slots Compressor CpSpecificHeatRatio CpDriverPower CpCompressibilityFactorOutlet CpCompressibilityFactorInlet CpActualGasFlowrateInlet Size Interactive Slots TurboExpander CpSpecificHeatRatio CpPowerOutput CpCompressibilityFactorInlet CpActualGasFlowrateInlet Size Interactive Slots HeatExchanger Heat Exchanger Area Minimum Overdesign Factor Overdesign Factor Final Surface Area LMTD Overall Heat transfer Coefficient Raw Surface Area Shell Side Fouling Resistance Shell Side Heat Transfer Coefficient Side For Hot Stream Surface Area with Overdesign Temperature Correction Factor Tube Side Fouling Resistance Tube Side Heat Transfer Coefficient UA Overall U Appendix A: Equipment and Slots of those Equipment Affected by Mapping 496 Size Interactive Slots HeatExchanger_PlateFin CpExchangerDepth CpExchangerLength CpExchangerVolume CpExchangerWidth CpRemarks2 : CpMaterialCostPerUnit CpLaborHoursPerUnit Size Interactive Slots - Pump CpLiquidFlowrate CpFluidViscosity CpFluidSpecificGravity CpFluidHead Size Interactive Slots Pump_Gear CpViscosityCS CpLiquidFlowrate CpFluidSpecificGravity CpFluidHead Size Interactive Slots Pump_Vacuum CpActualGasFlowrate CpLiquidFlowrate CpFluidViscosity CpFluidSpecificGravity CpFluidHead Size Interactive Slots Vessel_Horizontal Size Interactive Slots Vessel_Spherical Size Interactive Slots Vessel_Spheroid Size Interactive Slots Vessel_Vertical WFE WFE SYSTEM Heat transfer area : No. of identical items CpHeatTransferArea Appendix A: Equipment and Slots of those Equipment Affected by Mapping 497 Appendix A: Equipment and Slots of those Equipment Affected by Mapping 498 Index . .D01 file extension, Icarus Object files 128 .EML file extension, importing cost libraries 292 .UCL file extension, importing cost libraries 292 2 2/3 rule 89, 238 A About command Help menu 42 Absolute Basis streams 114, 117, 122–124, 178 Accelerated Cost Recovery System (ACRS) Investment Parameters, Depreciation Method 104 Accounting Rate of Return (ARR) Cashflow spreadsheet 453 ACRS See Accelerated Cost Recovery System (ACRS) Activate Custom Model option Preferences 49 Add Area command 182 Add button Pipe Details form 193 Wage Rate Info form 73 Add Entry for Reporting Assistant Run menu 39, 462 Add Project Component command 183 Add Stream button toolbar 37, 178 Index Add Stream command View menu, PFD 174 View menu, PFD 178 Add Trend Data to Database command Trend menu, Aspen Icarus Reporter 426 Adding areas 182 project components 182 streams 216–219 Additional Project Component files importing from 5.0/5.1 22 Adjusted Total Capital Cost Project Summary spreadsheet 447 AdminDir location, Preferences 50 AEM See Analyzer Economics Module (AEM) Air coolers design criteria specifications 89 Air supply instrumentation loop 196 All Crafts Percent of Base General Wage Rates 71 Allow Docking command 35 Analyzer 2.0B importing from 22–24 Analyzer Economics Module (AEM) 388–405 error when re-launching 400 loading 388 RESULTS workbook 393–398 revising premises 398–399 saving workbooks 400 SPECS workbook 389–393 Analyzer Scale-Up Module (ASM) 295–298 499 Analyzer Utility Model (AUM) notes 120 Anchor bolts civil installation bulk 194 Apply 2/3 Rule for Design Pressure Design Criteria 89 Apply button Develop Stream specifications form 116, 217 Installation Bulks form 188 Interactive Sizing form 224 Mat'l Man-hour Adjustments form 190 Preferences dialog box 47 Area adding 182 deleting 205 icons 27 importing 200 List view display of items 30 mapping 152 pop-up menu 183 re-numbering 205 simulator 144, 153, 158, 171 type 182 Area Information dialog box 182 Area title 199, 200 Areas dimensions 199, 200 electrical specifications 199, 200 equipment specifications 199, 200 index manhours 199, 200 index material costs 199, 200 insulation specifications 199, 200 paint specifications 199, 200 piping specifications 199, 200 steel specifications 199, 200 title 199, 200 type definition 199, 200 ARR(Accounting Rate of Return) Cashflow spreadsheet 453 ASME pressure vessel design code selection 65 Aspen Icarus Reporter accessing 406 creating a user database 430 Data trending 426 Excel reports 418–425 HTML reports 416–418 importing data 429 Management reports 418–421 Index menu bar 408 report mode 408 standard reports 408–416 Aspen Plus link to IPE 135 map specs 82 models used in sizing towers 243 AspenTech Aspen Plus simulator program 82 Auto Filter 425 Automatic Item Evaluation checked command Tools menu 41, 464 Automatic task backup 49 B Backup options Preferences 49 Base Design Value Analyzer Economics Module (AEM) 398, 399 Base Stream Develop Stream specifications form 117 Develop Streams dialog box 122–124, 178 BaseCase, default scenario name 19 Basis Map dialog box 153 streams 114, 117, 124, 122– 124, 178 Basis for Capital Costs construction workforce 70–73 indexing 74 input units of measure 59 introduction 58 libraries 125, 126 output (reports) units of measure customization 61 selecting defaults 126 BFD See Block Flow Diagram (BFD) BinCacheDir location, Preferences 50 Block Flow Diagram (BFD) displaying 146 Drag & Find feature 147 introduction 146 right-click commands 148 View menu 150 Zoom commands 148–149 Bottom sump height 500 towers, design criteria 90 BS5500 pressure vessel design code selection 65 Buildings 181 By-products escalation 404 Stream Input worksheet 405 C Cached project information 44 Cancel button Develop Stream specifications form 116 Preferences dialog box 47 Capacity changing 295 Capacity over-design factor See Pump overdesign factor Capital cost parameters Project Input worksheet 403 Capital Costs Cashflow spreadsheet 451 depreciation 103–104, 451 errors 387 escalation 104, 447, 450 Executive Summary spreadsheet 455 Investment Parameters 105 Project Summary spreadsheet 444, 446–447 reports 48, 435, 437 toolbar button 37, 406, 431 View command 40, 150, 173, 406, 431 Capital investment Project Input worksheet 402 Capture worksheet Analyzer Economics Module (AEM) 393 Cascade command Window menu 28, 42 Cash Flow Summary reports, Icarus Editor 437 Cash flows Project Input worksheet 401 Cashflow spreadsheet 449–454 CASHFLOW.ICS Cashflow spreadsheet 449–454 ChemCAD map specs 83 Index simulator report preparation 136–137 Chemstations link to IPE 11, Also See ChemCAD Civil installation bulk 194 material costs and man-hours 189 Clear All Saved Trends command Trend menu, Aspen Icarus Reporter 426 ClipboardDir location, Preferences 50 Close command File menu 38 COA See Code of Account (COA) COADir location, Preferences 50 Code of Account (COA) allocating UCL item costs to 284 Cold Inlet Stream field 224 Cold Outlet Stream field 224 Color coding Component Specifications form 187 Component Map Information 156, 158 Component Name 157 Component Specifications form accessing 186 color coding 186, 187 Options button 187, 188 P&ID button 191, 194 Component Status 157 Components See Project components Components view Palette 33 ComponentsDir location, Preferences 50 Compressors design criteria specifications 89 sizing 214 Computer name scenario information 25 Configuration options mapping 154, 158 Construction workforce 70–73 Construction schedule Project Schedule Data Sheet 438 Contingency 501 General Specs 63, 64, 66 Project Summary spreadsheet 447 Contingency Percent field General Specs 63, 64 Contractor fees 447 reports 438 Control Center button bar 344 Control centers instrumentation loop 196 Control Panel worksheet Analyzer Economics Module (AEM) 389 Control signal instrumentation loop 196 Control valve instrumentation loop 196–197 Copy button toolbar, Icarus Editor 433 Copy command library items 291 project components 202, 204 Cost libraries deleting 294 duplicating 293 Equipment Model Library (EML) 277–281 importing 292 introduction 276 Unit Cost Library (UCL) 281–287 Costs See Capital costs; Direct costs; Equipment; Labor; Operating costs; Project cost; Project direct costs; Total direct cost; Total project cost; Utility costs Design Basis worksheet 395 distribution graph, Figures worksheet 397 EPC worksheet 393 Country Base 21 Craft code 74 Craft rates construction workforce 73–74 Create New Project dialog box 18, 22 Create New Trend in Excel command Trend menu, Aspen Icarus Reporter 427 Create Stream dialog box 121, 123, 217, 218 Index Create tab view Develop Streams dialog box 121 Create User Database command File menu, Aspen Icarus Reporter 408, 430 Create User Database dialog box Aspen Icarus Reporter 430 Creating project scenarios 18–22 streams 216–219 Creating a new project 18 Currency Analyzer Economics Module (AEM) 388, 393 Currency Conversion Rate creating a project 21 Executive Summary spreadsheet 455 General Project Data 21, 58 Project Summary spreadsheet 443 Currency Name 21 Currency Symbol 21 Current Map List Project Component Map Specifications dialog box 81 Custom Model instructions 206–210 Preferences 49 Custom Tasks command Tools menu 41 Cut command project components 203 Cyclone inlet linear velocity design criteria specifications 98 D Data trending Aspen Icarus Reporter 426 DC_V worksheet Analyzer Economics Module (AEM) 390 Decision Analyzer command Run menu 388 Decision Analyzer dialog box 388 Decision Center worksheet Analyzer Economics Module (AEM) 390 Delete button Pipe Details form 193 Delete Mappings command 158 Deleting 502 areas 205 components 204 mappings 158 projects and project scenarios 43 Density Develop Stream specifications form 118 Depreciation expense Cashflow spreadsheet 451 Depreciation method Project Input worksheet 404 Depreciation Method Cashflow spreadsheet (CASHFLOW.ICS) 450, 451 Investment Parameters 103 Project Summary spreadsheet (PROJSUM.ICS) 445 Design code Executive Summary spreadsheet 456 Project Summary spreadsheet 443 Design Code General Specs 65 Design Criteria libraries 125 selecting defaults 126 Design Criteria specifications 86 Design pressure applying 2/3 rule for 90, 238 design criteria specifications 87 sizing agitators 233 sizing heat exchangers 239 sizing towers 249 utility specifications 101 Design temperature design criteria specifications 88 sizing agitators 233 sizing heat exchangers 239 sizing towers 249 utility specifications 100 Desired Rate of Return Cashflow spreadsheet (CASHFLOW.ICS) 450 Executive Summary spreadsheet (EXECSUM.ICS) 455 Investment Parameters specifications 103 Project Summary (PROJSUM.ICS) spreadsheet 445 Index Detailed Process Economics reports Error! Not a valid bookmark in entry on page 388 Develop Equipment Library Model form 279 Develop Product Specifications dialog box 112 Develop Stream specifications form 116, 217, 219 Develop Streams dialog box 121, 122, 217, 218 Develop Utiltiy Specifications dialog box 99 Dimensions, areas 199, 200 DIN pressure vessel design code selection 65 Direct costs Also see Total direct cost Directories project, locations - Preferences 50–53 Disconnect command streams 180 Disconnected Streams dialog box 180 Discounted cash-flow rate of return See Internal Rate of Return (IRR) Display results after evaluation Preferences 48 Docking 35 Documentation 15 Double Declining (Balance) Investment Parameters, Depreciation Method 103 Draw Disconnected Stream button toolbar 180 Draw Disconnected Stream button toolbar 37 Draw Disconnected Stream command View menu, PFD 180 Draw Disconnected Stream command View menu, PFD 174 Duct installation bulk 193 E Earnings Cashflow spreadsheet 452 Economic Life of Project 503 Investment Parameters 103 Project Summary spreadsheet (PROJSUM.ICS) 445, 450 ECOSYS.xls 388, 399 Edit Connectivity button toolbar 37, 175, 176 Edit Connectivity command View menu, PFD 174, 175 Electrical installation bulk 197 material costs and man-hours 189 specs, areas 199, 200 Electricity operating unit costs specifications 108 E-mail reports 418, 419, 424 EML See Equipment Model Library (EML) Engineering schedule Project Schedule Data Sheet 438 Engineer-Procure-Construct (EPC) period Cashflow spreadsheet (CASHFLOW.ICS) 450 Executive Summary spreadsheet (EXECSUM.ICS) 455 Investment Parameters 104 Engineer-Procure-Construct period Project Summary spreadsheet (PROJSUM.ICS) 444, 445 EPC See Engineer-ConstructProcure (EPC) period EPC Phase Project Input worksheet 403 EQUIP.ICS investment analysis spreadsheets 441 Equipment adding 182 cost 442 specifications, areas 199, 200 Equipment Model Library (EML) adding an item to 278 adding EML item as a component 280 creating 277 definition 276 EMLDir, location 50 Equipment Summary investment analysis spreadsheets 441 Index ERROR message 387 Error Messages command View menu 40 Escalating library costs 291 Escalation Cashflow spreadsheet (CASHFLOW.ICS) 450, 451 cost libraries 291 Investment Parameters 104 Project Basis worksheet, Analyzer Economics Module (AEM) 395 Project Input worksheet 404 Project Summary spreadsheet (PROJSUM.ICS) 445, 447 Estimate Class 58 Estimate Date 58 Evaluate button Component Specifications form 187, 463 Evaluate Item command 463 Evaluate Project button toolbar 37, 386 Evaluate Project command Run menu 39, 386 Evaluation item 463 Preferences 48 project 386 Evaluation Engine 241, 430 Excavation and backfill civil installation bulk 194 Excel Analyzer Economics Module (AEM) 388–405 Excel Custom Model files 206–210 Excel reports Auto Filter 425 descriptions 422 opening 422 Exchange rate See Also Currency Conversion Rate Analyzer Economics Module (AEM) 393, 401 EXECSUM.ICS 454–456 Executive Summary spreadsheet 454–456 Exit command IPE File menu 40–42 Expenses Cashflow spreadsheet 452 Export to Excel Trending Report dialog box 504 Aspen Icarus Reporter 427 Export to Excel Workbook dialog box Aspen Icarus Reporter 419, 423 Export to SPECS Command File menu 38 Export Trend Data into Excel dialog box Aspen Icarus Reporter 428 External Simulation Import Tool command Tools menu 41 External Simulation Import Tool command Tools menu 139–141 F Facility Type Investment Parameters 105 FATAL message 387 Figures worksheet Analyzer Economics Module (AEM) 397 File menu Aspen Icarus Reporter menu bar 408 IPE menu bar 38 Fit into one page Zoom dialog box 149 Float in Main Window command 35 Flow rate units product specifications 113 Fluid classes utility streams 99 Foaming tendency trayed towers, design criteria 92 Foreman wage rate general wage rates 73 Form work civil installation bulk 194 Fraction basis 119 Freeze Content button Properties Window 34 Freight General Specs 64 Fuel operating unit costs specifications 108 Furnace fractional efficiency heat exchanger design criteria 89 FVI (Future Value of Inflows) Cashflow spreadsheet 452 Index G G and A Expenses Cashflow spreadsheet (CASHFLOW.ICS) 450 Investment Parameters 105 Project Summary spreadsheet (PROJSUM.ICS) 446 Galvanizing (for steel) paint installation bulk 198 General and administrative costs Investment Parameters 105 Project Summary spreadsheet (PROJSUM.ICS) 446 General investment parameters Project Input worksheet 404 General Project Data creating a new project scenario 21 project specifications 57 General rates construction workforce 70–73 General Specs 62–65 Gray borders Component Specifications form 187 Green borders Component Specifications form 187 Grid Settings command View menu, PFD 174, 175 Grids viewing in Block Flow Diagram (BFD) 151 viewing in Process Flow Diagram (PFD) 175 Grids Visible command View menu, BFD 151 Grout civil installation bulk 194 H Heat exchangers design criteria specifications 90 sizing 238–240 utility specifications 98 Help menu 42 Helper wage rate general wage rates 72 HETP (height equivalent of a theoretical plate) packed towers, design criteria 91 505 Hot Inlet Stream field 221 Hot Outlet Stream field 224 HTML reports descriptions 416 Item Report 48 opening 417, 418 Hyprotech link to IPE 11, Also See HYSIM, HYSYS HYSIM map specs 84 models used in sizing towers 243 simulator report preparation 137–139 HYSYS map specs 85 models used in sizing towers 243 simulator report preparation 139–141 I Icarus Editor printing report 433 printing report section 432 reviewing results 431–440 toolbar 432 Tools menu 41 Icarus Evaluation Engine (IEE) 241, 430 Icarus interface 26–36 Icarus Object files 128 Icarus Project Component Selection dialog box 156, 280, 285, 288 IEE See Icarus Evaluation Engine (IEE) Import command File menu 38 Libraries view, Palette 127, 292 Import Connected Streams option Preferences 49 Import Data command File menu, Aspen Icarus Reporter 408 File menu, Aspen Icarus Reporter 429 Import Installation Bulks option Preferences 49 Import Selection dialog box Aspen Icarus Reporter 429 Importing areas 200 Index components 200 project from previous version 22–24 scenarios 201 specification files 127 Inch-Pound (IP), units of measure 20, 126, 127 Incomplete items 31 Indexing Project Basis specifications 74 Indicating signal instrumentation loop 196 Indirect costs general wage rates 71 Project Summary spreadsheet 447 reports 447 Unit Cost Library (UCL) 276 Indirects general wage rages 71 INFOmational message 387 Input Units of Measure Specifications dialog box 20, 59 Installation bulks accessing 188 civil 194 duct 193 electrical 197 instrumentation 194 insulation 197 introduction 188 material man-hour additions 191 paint 198 pipe details 191 pipe spec 191 Preferences 48 steel 194 Instrument air operating unit costs specifications 108 utility costs, Project Summary spreadsheet 449 Instrument volumetric model 194– 196 Instrumentation installation bulk 194 loop adjustments 196–197 material costs and man-hours 189 Insulation installation bulk 197 material costs 189 506 Interactive sizing 213–219 Interactive Sizing form 153, 157, 220, 224 Interest rate Project Input worksheet 404 Interface layout 26–36 Save Window States option 48 Internal Rate of Return (IRR) Cashflow spreadsheet 453 Statements worksheet 396 Status worksheet 393 Investment Analysis project specifications 101–114 viewing in MS Excel 441 Investment Analysis View command View menu 40, 441 Investment Parameters libraries 125 project specifications 101–108 selecting defaults 126 IP, units of measure 20, 126, 127 IPE 5.0/5.1 importing from 22–24 IPELog.txt Preferences, Logging 53 IRR (Internal Rate of Return) Cashflow spreadsheet 453 Item evaluation 463 automatic 464 Item Report instructions for running 463 Preferences 48 Item Report command 463 J JIS pressure vessel design code selection 65 Job Number field 58 Junction boxes instrumentation loop 196 L Labor cost per unit Unit Cost Library (UCL) 284 Labor hours per unit Unit Cost Library (UCL) 284 Labor Unit Costs Index operating unit costs specifications 107, 108 Laboratory charges Project Input worksheet 403 Laboratory Charges Investment Parameters 105 Project Summary spreadsheet 444, 446 Ladders, steel - installation bulks 194 Length of Start-up Period Investment Parameters 106 Libraries Basis for Capital Costs 59, 125 cost libraries 262–294 Design Criteria 125 Equipment Model Library (EML) 277 input units of measure 59–60 moving to another directory 129 Project Component Map Specifications 125 specification libraries 125–129 Unit Cost Library (UCL) 281 Utility Specifications 125 view 32 Liquid entrainment method 95, 257 List view description 30 mapped components 157 simulator file name 144 Status column 157, 184 Load Data button toolbar 37, 144 Load Data command Run menu 39, 144 Locations plant relocation 295 plant/project location 64, 443 Preferences 50–53 Logging Preferences 53 Loops instrumentation installation bulks 194 modifications 196–197 M Magnification Aspen Icarus Reporter 410 Block Flow Diagram (BFD) 148– 149 507 Main product Project Summary spreadsheet 448 Main Window display options 35 interface, default position 26 printing 38 understanding 28–29 Management reports 418–421 Man-hour indexing 74 Manpower Productivity Expert (MPE) Tools menu 41 Manufacturing cost parameters Project Input worksheet 403 Map All Items option Map dialog box 153 Map command pop-up menu 152 Map dialog box 152 Map Items button toolbar 151 Map Items command Run menu 39, 151 Map Selected Item(s) option Map dialog box 153 Map Unsupported Models To Quoted Cost Item Preferences, Process tab 49 Mapping simulator models instructions 151–158 specifications 81 units of measure mapping specs 77–80 unsupported models 49, 82 Mass flow Develop Stream specifications form 118 Material adjustments indexing, area level 199, 200 Material and man-hour additions installation bulks 191 Material and man-hour adjustments installation bulks 189, 208 Material and man-hour indexing 74 Material cost per unit Unit Cost Library (UCL) 284 Material costs indexing 74 Material Index Info form 75 Material streams product specifications 111 Index Mean temperature difference (MTD) 238 Menu bar Aspen Icarus Reporter 408 IPE 26, 40–42 Metric, units of measure 20, 126, 127 Microsoft Access Database (.mdb) file 430 MIRR (Modified Internal Rate of Return) Cashflow spreadsheet 453 Mixture button Develop Stream specifications form 116 Mixture Specs developing streams 118 Modify command simulator block 145 streams 180 Modify tab view Develop Streams dialog box 115 MTD See Mean temperature difference (MTD) Multi-core runs instrumentation loop 196 MUSE design criteria specifications 89 N Net Earnings Cashflow spreadsheet 452 Net Present Value (NPV) Cashflow spreadsheet 453 Statements worksheet 396 Status worksheet 393 Net Return Rate (NRR) Cashflow spreadsheet 453 New command File menu 18, 22, 38 New Component Information dialog box 184 New Project button toolbar 18, 37 NPV (Net Present Value) Cashflow spreadsheet 453 NRR (Net Return Rate) Cashflow spreadsheet 453 Number of Periods for Analysis Investment Parameters 103 Number of shifts 71 Project Input worksheet 403 508 Number of Weeks per Period Investment Parameters 103 O OK button Develop Stream specifications form 116 Installation Bulks form 48, 189 Mat'l Man-hour Adjustments form 190 Open button toolbar 24, 37 Open command File menu 24, 38 Palette Projects view 25 Open Existing Project dialog box 24 Open Workbook command File menu, Aspen Icarus Reporter 408, 425 Opening an existing project 24 Operating and Maintenance Labor Escalation Investment Parameters 104 Project Summary spreadsheet (PROJSUM.ICS) 445 Operating charges Cashflow spreadsheet 450 Investment Parameters 105 Project Input worksheet 403 Project Summary spreadsheet 444, 446 Operating costs Cashflow spreadsheet 451 Figures worksheet 397 introduction to IPE 12 Investment Parameters 105 product specifications needed to evaluate 113 Project Summary spreadsheet 444 raw material specifications needed to evaluate 109 Operating Hours per Period Investment Parameters 106 Project Summary spreadsheet 444 Operating labor and maintenance Project Input worksheet 403 Operating labor and maintenance costs Cashflow spreadsheet 450 Investment Parameters 105, 107 Index Project Summary spreadsheet 445, 446, 448–449 Operating Mode Investment Parameters 106 Operating supplies Project Input worksheet 403 Operating Supplies Investment Parameters 105 Project Summary spreadsheet 444 Operating Unit Costs libraries 125 project specifications 107– 108 selecting defaults 126 Options button Component Specifications form 187, 188 Options menu Component Specifications form 49, 187, 188 Options sub-menu Tools menu 41 Order Number 205 Overall column efficiency design criteria specifications 93 tower sizing 251 Overdesign factor 225 heat exchangers 90, 239 pumps 88 Overtime hours,general wage rates 72 rate, general wage rates 72 Overwrite Project Backups option 48, 49 P P&ID button 191, 194 Packed towers design criteria specifications 91 sizing 254, 255 Paint material costs 189 specs, areas 199, 200 Palette Components view 33, 183 cost libraries 277–294 deleting a project from 44 description 32–34 Docking and undocking 35 dragging components from 183 floating in Main Window 35 509 hide/display 33 interface, default position 26 Libraries view 32, 125–129, 277–294 opening projects 25 Projects view 25, 32, 33, 44, 46, 51 Recent Items folder 183 specification libraries 125 unlocking projects from 46 View menu 40, 173 Paste button toolbar, Icarus Editor 433 Paste command project components 202, 204 Patents and royalties Project Input worksheet 403 Payout period Cashflow spreadsheet 453 Period Description Investment Parameters 102 Phase durations Project Input worksheet 403 Phases Stream Input worksheet 405 PI (Profitability Index) Cashflow spreadsheet 454 Pile types 67 Pipe Details installation bulk 191 Pipe Spec installation bulk 191 Pipe volumetric model 192–193 Piping installation bulks 191–193 material costs and man-hours 189 volumetric model 192 Piping and Instrumentation Drawings (P&ID) manual 191, 194 Piping specifications areas 199, 200 Plant bulks component categories 181 difference from installation bulks 188 Plant capacity changing 295 Plant location changing 295 Plant Overhead Cashflow spreadsheet 450 Investment Parameters 105 Index Project Summary spreadsheet 444, 446 Platforms, steel - installation bulks 194 PO (Payout Period) Cashflow spreadsheet 453 PODE (Payout Period Desired Cashflow spreadsheet 450 Ports Visible button toolbar 37, 175 Ports Visible command View menu, PFD 174 Potable water operating unit costs specifiations 108 utility costs, Project Summary spreadsheet 449 Precooler suffix for mapping 155 tower configurations 159, 245, 247 Preferences accessing 46 Backup tab view 49 buttons 46 description 46 General tab view 47 introduction 46 Locations tab view 50–53 Logging tab view 53 Process tab view 49 prompts 47 saving window states 48 Tools menu 41 Prepared By field general project date 58 Present Value of Cashflows Cashflow spreadsheet 452 Pressure vessel design code General Specs 65 Primary fluid component 116, 119, 217 Print command IPE File menu 38 Print Preview command File menu 38 Print Setup command File menu 38 Printing Aspen Icarus Reporter 412 forms and reports in Main Window 38 Icarus Editor 432 510 Pro/II models used in sizing towers 243 R/R minimum 90 simulator report preparation 141–142 Problem description SimSci report preparation 142 Process Complexity contingency affected by 66 General Specs 63 Process connection intrumentation loop 196 Process Control General Specs 64 Process Description contingency affected by 66 equipment design allowance affected by 66 General Specs 63 Process Design specifications 77– 101 Process equipment 181 Process Flow Diagrams (PFD) 171– 180 Process Fluids Investment Parameters 106 Process options Preferences 49 Process Stream field product specifications 113 raw material specifications 110 Process vessel height to diameter ratio design criteria specifications 94 vessel sizing procedure 259, 261 Product escalation Project Input worksheet 404 Product sales per hour, Project Summary spreadsheet 448 per period, Project Summary spreadsheet 448 total, Project Summary spreadsheet 446 Product specifications investment analysis specifications 111–114 libraries 126 selecting defaults 126 Product Support on the Web command Help menu 42 Production Index Stream Input worksheet 405 Production operations Stream Input worksheet 405 Productivity adjustments 71 Products Escalation Investment Parameters 104 Project Summary spreadsheet 445 Profitability Index Cashflow spreadsheet 454 Project areas See Area Project Basis Basis for Capital Costs 58–74 default specifications 125 General Project Data 57 introduction 55 Investment Analysis 101–114 Process Design 77–101 Project Properties 56 specification libraries 125 Streams 114–125 Project Basis view 27 Project Basis worksheet Analyzer Economics Module (AEM) 395 Project Capital Escalation Cashflow spreadsheet 450, 451 Investment Parameters 104 Project Summary spreadsheet 445, 447 Project capital evaluation Project Input worksheet 404 Project component connecting to stream 176 Project Component Map Preview dialog box 154, 156, 158 Project Component Map Specifications dialog box 80 libraries 125 project specifications, Process Design 80–86 selecting defaults 125 Project components adding 182 component specifications 186 copying 202 deleting 204 Equipment Model Library (EML) items 280 importing 200 installation bulks 188 re-numbering 204 511 Unit Cost Library (UCL) item 285 Project cost Cashflow spreadsheet 450 contingency percentage 63 Project Summary spreadsheet 447 Project Data Sheet reports, Icarus Editor 436 Project Description Project Properties 19, 56 Project Summary spreadsheet 442 Project directories alternate directories 51 copying 46 default, setting 52 Project evaluation Preferences 48 running 386 scan for errors 48, 386 Project Explorer 26, 27 Docking and undocking 35 floating in Main Window 35 interface, default position 26 relation to Palette 32 View menu 40, 173 Project in use - message 45 Project Input worksheet Analyzer Economics Module (AEM) 390, 398–399 Analyzer Economics Module (AEM) 400–404 Project Location General Specs 64 Project Name Aspen Plus - IPE simulator link 135 Cashflow spreadsheet 454 Create New Project dialog box 19, 23 Project Summary spreadsheet 442 Save As dialog box 43 Project Properties creating a new project 19 Project Basis specifications 56 Project scenarios creating new 18 deleting 43 importing 201 opening existing 24 salvaging 44 saving 42 Index unlocking 45 Project Schedule Data Sheet reports, Icarus Editor 438 Project Summary reports, Icarus Editor 435 Project Summary spreadsheet (PROJSUM.ICS) 442–449 Project Title General Project Data 58 Project Summary spreadsheet 443 Project Type contingency affected by 66 Executive Summary spreadsheet 456 General Specs 63, 64 Project Summary spreadsheet 443 Project view 27 Projects copying 46 creating 18–22 deleting 43 opening existing 24 view 32, 33 PROJSUM.ICS investment analysis 442–449 Prompts Preferences 47 Properties Window description 34 Docking and undocking 35 floating in Main Window 35 Freeze Content button 34 interface, default position 26 relationship to specifications form 34, 186 View menu 40, 173 PROVISION See SimSci's Pro/II with PROVISION Pump overdesign factor design criteria specifications 88, 241 sizing procedures 241 Pumps design criteria specifications 88 sizing 214 PV (Present Value) Cashflow spreadsheet 452 PVI (Present Value of Inflows) Cashflow spreadsheet 452 PVO (Present Value of Outflows) Cashflow spreadsheet 452 512 PVOP (Present Value of Outflows – Products) Cashflow spreadsheet 452 PVOS (Present Value of Outflows – Sales) Cashflow spreadsheet 452 Q Question mark in Status column component specifications 157, 186 Quoted cost item mapping overhead/bottoms split to 245 mapping unsupported models to 49 Quoted cost items mapping unsupported models to 81 Quoted equipment 181, 188 R Rate field product specifications 113 raw material specifications 110 Rate Units field product specifications 113 raw material specifications 110 Raw material costs, Cashflow spreadsheet 450 costs, Executive Summary spreadsheet 455 costs, project specifications 111 costs, Project Summary spreadsheet 446, 447 escalation 104, 445, 450 project specifications 108–111 Raw Material Escalation Cashflow spreadsheet 450 Investment Parameters 104 Project Summary spreadsheet 445 Raw Material Specifications investment analysis, project basis 108–111 libraries 126 selecting defaults 126 Raw materials escalation 404 Stream Input worksheet 405 Rebar Index civil installation bulk 194 Recent Items folder 183 Reconnect Sink command stream, Process Flow Diagrams (PFD) 180 Reconnect Source command streams, Process Flow Diagram (PFD) 180 Red borders Component Specifications form 187 Refrigerant 222 Relation attributes 430 Relative Basis streams 114, 117, 122–124, 178 Relocating introduction 12 Remarks field project properties 20 Project Properties 56 Re-number command Run menu 205 Re-numbering areas 205 project components 204 Report files Reporting Assistant 457 Report templates Reporting Assistant 457 Reporter See Aspen Icarus Reporter Reporting Assistant 456–462 Reports Analyzer Economics Module (AEM) Error! Not a valid bookmark in entry on page 388 customizing 456–462 data trending 426–428 Excel Error! Not a valid bookmark in entry on page 388, 418–425 HTML 416–418 Item report 463 Management reports 418 producing 386, 388, 463 Standard reports 408–416 Reroute All Streams command Run menu 172 Reset button Develop Stream specifications form 116 Residence time 513 design criteria specifications 92, 94 sizing crystallizers 235 sizing vessels 256, 259, 261 Re-Size command project component pop-up menu 153, 215 RESULTS workbook Analyzer Economics Module (AEM) 393–398 Revenue Cashflow spreadsheet 451–454 Royalties See Patents and royalties, Project Input worksheet Run Report command File menu, Aspen Icarus Reporter 408 S Sales Cashflow spreadsheet 450 Salvage Project As dialog box 45 Salvage Value Project Input worksheet 404 Salvage Value (Percent of Initial Capital Cost) Cashflow spreadsheet 450 impact on depreciation 103 Investment Parameters 103 Project Summary spreadsheet 445 recouped 453 Salvaging project scenarios 44 Save As command File menu 38, 43 Save button toolbar 37, 42 Save command File menu 38, 42 Save Project As dialog box 43 Save Window States checkbox Preferences 48 Saving cached information 44 project scenarios 42 window states 48 Scan for Errors before evaluation Preferences 48 Scan Messages 387 Scenario Description General Project Data 58 Index Project Summary spreadsheet 443 Scenario Name creating a new project 19 importing Standard Basis from 5.0 23 Project Summary spreadsheet 443 Scenario reporting Project Input worksheet 401 Scenarios creating 18–22 importing 201 opening existing 24–25 Schedule Project Input worksheet 401 Project Schedule Data Sheet 438 Screens design criteria specifications 97 Select a Suffix dialog box 155 Select command Project Basis pop-up menu 129 Select Import Type dialog box 23 Select Simulator Type dialog box 143 Sensor instrumentation loop 196–197 Separation factor design criteria specifications 95 sizing vessels 256, 257 Show Page Bounds View menu, BFD 151 View menu, PFD 174 Sieve tray design 253 Signal cabling, instrumentation installation bulks 194 SimSci's Pro/II with PROVISION models used in sizing towers 243 R/R minimum 90, 255 SHORTCUT column operation 255 simulator report preparation 141–142 Simulation reports Aspen Plus 132–135, 243, 245 ChemCAD 136–137 HYSIM 137–139, 243, 245 HYSYS 139–141, 243, 245 loading 28 Pro/II 141–142, 243 selecting 144 514 Simulation Sciences Also See SimSci's Pro/II with PROVISION link to IPE 11 Simulator data loading 143–145 mapping 151–158 mapping specifications 81 unsupported models 49 Simulator File Name project specifications, Process Design 143 Simulator Type Executive Summary spreadsheet 455 project specifications, Process Design 143 Project Summary spreadsheet 442 Simulator Units of Measure Mapping Specs libraries 126 project specifications, Process Design 77–80 selecting defaults 126 Single Component Summary Report Preferences 48 Site development 181 Size button 213, 220 Size Icarus Project Component(s) options Map dialog box 153 Size Item option 177, 213 Sizing calculations 230–261 ChemCAD items 137 defaults 230–261 HYSIM items 138 mapped components 153, 157, 213 overview 213 parameters 87, 89, 91, 92, 94, 96, 98 requirements 230–261 Sizing Expert 98, 153, 177, 213– 219 Sizing Method field Equipment Model Library (EML) 279 Snap to Grid checkbox Grid properties 175 Snap to Grid command Index View menu, BFD 151 View menu, PFD 174 Soil conditions General Specs 64, 67 Solids handling information design criteria specifications 97 Source Map dialog box 153 Specification basis product specifications 113 raw material specifications 110 Specification files creating 126 deleting 128 duplicating 128 importing 127 introduction 125 modifying 127 moving to another directory 129 selecting 129 Specification libraries customizing 126–129 introduction 125 moving to another directory 129 SPECS workbook Analyzer Economics Module (AEM) 389–393 Spreadsheets customizing 456–462 SQL database exporting to Microsoft Access 430 Stairs, steel - installation bulks 194 Standard Basis file, selecting 129 input file, General Project Data 57 Standard reports descriptions 408, 413–412 navigating 410 opening 409 printing 412 searching 412 Start date, basic engineering Executive Summary spreadsheet 455, 456 General Specs 64 Project Summary spreadsheet 443, 444, 447 Starting program 17 Start-up period, length Investment Parameters 106 Statements worksheet 515 Analyzer Economics Module (AEM) 396 Status bar 26 View menu 40, 173 Status column List view 157, 184 Status worksheet Analyzer Economics Module (AEM) 393 Steam utility 222 Steel installation bulk 194 material costs and man-hours 189 specifications, areas 199, 200 Straight Line Investment Parameters, Depreciation Method 103 Stream Input worksheet Analyzer Economics Module (AEM) 404–405 Analyzer Economics Module (AEM) 398–399 Analyzer Economics Module (AEM) 390 Streams absolute basis 123 adding 121, 177 basis mode 123 connecting to equipment during sizing 219–226 connectivity, Process Flow Diagram (PFD) 175 creating 121, 177 creating from Project Explorer 216–219 deleting 124, 180 material 111 modifying 115 process 113 product specifications 111 relative basis 123 Streams List command View menu, BFD 151 View menu, PFD 174 Subcooling tower configurations 159 Suffixes mapping 154, 155 Sum of the Digits Investment Parameters, Depreciation Method 103 Supervision Index costs, Project Input worksheet 404 System administration files locations, Preferences 50 System cost base date Executive Summary spreadsheet 456 Project Summary spreadsheet 443 T Tax Rate Cashflow spreadsheet 450 Investment Parameters 103 Project Summary spreadsheet 445 Taxes amount owed, Cashflow spreadsheet 452 General Specs 64, 66 indirects, Project Summary spreadsheet 447 Template files Reporting Assistant 458 TEX (Total expenses) Cashflow spreadsheet 452 Tile command Window menu 28, 42 Time period Project Input worksheet 402 Timed backup 49 Toolbar buttons 36 description 36 docking 36 interface, default position 26 View menu 40, 173 Tools menu 41 Total direct cost Capital Cost report, Icarus Editor 440 Equipment Summary spreadsheet (EQUIP.ICS) 442 Total earnings Cashflow spreadsheet 452 Total Expenses Cashflow spreadsheet 452 Total Manpower Schedule reports, Icarus Editor 436 Total Operating Cost, Executive Summary spreadsheet 455 Total project cost 516 Cashflow spreadsheet 450 Project Summary spreadsheet 447 Tower configurations mapping 154, 161–169, 245– 248 Training command Help menu 42 Transducers instrumentation loop 196 Transmitters, instrumentation installation bulks 194 Trayed towers design criteria specifications 92 sizing 251, 252, 255 Trend menu, Aspen Icarus Reporter 408, 426, 427 Trending database reports 426– 428 Trim cooler suffix for mapping 155 tower configurations 159, 245, 247 Type definition, area 199, 200 U UCL See Unit Cost Library (UCL) Unique Project Backup options 49 Unit Cost field product specifications 114 raw material specifications 111 Unit Cost Library (UCL) adding an item to 283 adding UCL item to a project 285 creating 282 definition 276 Units of measure input customization 20, 59 output (reports) customization 61 project properties 20 scenario information 25 Unit Cost Library (UCL) 284 Units of Measure Specification dialog box 78 Unlock command 45 Unsupported simulator models Preferences 49 Update button Develop Stream specifications form 116 User Custom Model 206–210 Index User name scenario information 25 Utilities escalation 404 list of availiable utility resources 222 Stream Input worksheet 405 usage estimation 119 Utilities Escalation Cashflow spreadsheet 450 Investment Parameters 104 Project Input worksheet 404 Project Summary spreadsheet (PROJSUM.ICS) 445 Utility costs Cashflow spreadsheet 450 Executive Summary spreadsheet 455 heat-transfer utilities 101 non-heat transfer utilities 108 Project Summary spreadsheet 449 Utility Specifications libraries 125, 126 project specifications 98–101 selecting defaults 126 Utility stream creating 98 modifying 98 Utility Unit Costs operating unit costs specifications (non-heat transfer utilities) 108 utility specifications (heattransfer utilities) 101 V Valve tray sizing 253 Vapor disengagement height towers, design criteria 90 Version scenario information 25 Vessel design criteria specifications 95– 97 diameter, General Specs 65 height to diameter ratio 94, 259, 261 sizing 214, 255 View Existing Trend Data command Trend menu, Aspen Icarus Reporter 408, 429 517 View menu 40, 173 W Wage rates construction workforce specifications 70–73 WARNing message 387 What-You-See-Is-What-You-Get Zoom dialog box 149 Window menu 42 Window states, saving 48 Workbook mode understanding 28–29 View menu 40, 173 Workforce reference base General Wage Rates 71 Working capital Project Input worksheet 403 Working capital percentage Project Input worksheet 399 Working Capital Percentage Investment Parameters 105 WYSIWYG Zoom dialog box 149 Z Zoom Aspen Icarus Reporter 410 Block Flow Diagram (BFD) 148– 149 toolbar 37 Index 518 Index 519 Index 520

Aspen IPE User Guide

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