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reduce tolerance for recycle #1123

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Sep 29, 2024
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reduce tolerance for recycle #1123

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e25cc81
reduce tolerance for recycle
EvenSol Sep 29, 2024
7e4b76e
increased tolerance
EvenSol Sep 29, 2024
3c36b27
update test
EvenSol Sep 29, 2024
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5 changes: 2 additions & 3 deletions src/main/java/neqsim/processSimulation/processEquipment/util/Recycle.java
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Original file line number Diff line number Diff line change
Expand Up @@ -28,7 +28,7 @@ public class Recycle extends ProcessEquipmentBaseClass implements MixerInterface
protected StreamInterface mixedStream;
StreamInterface lastIterationStream = null;
private StreamInterface outletStream = null;
private double tolerance = 1e-4;
private double tolerance = 1e-2;
private int priority = 100;
private double error = 1e10;
private double errorFlow = 1e10;
Expand All @@ -38,7 +38,7 @@ public class Recycle extends ProcessEquipmentBaseClass implements MixerInterface

double compositionAccuracy = 1.0;
double temperatureAccuracy = 1.0;
double flowAccuracy = 1.0;
double flowAccuracy = 1.0e-2;

/**
* <p>
Expand Down Expand Up @@ -354,7 +354,6 @@ public double massBalanceCheck2() {
Math.abs(mixedStream.getFlowRate("kg/sec") - lastIterationStream.getFlowRate("kg/sec"))
/ mixedStream.getFlowRate("kg/sec") * 100.0;
}

return abs_sum_errorFlow;
}

Expand Down
116 changes: 53 additions & 63 deletions src/test/java/neqsim/processSimulation/processSystem/OilGasProcessTest.java
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Original file line number Diff line number Diff line change
Expand Up @@ -47,44 +47,40 @@ public void runProcess() throws InterruptedException {
thermoSystem.addPlusFraction("C38_C80", 1.0, 662.0 / 1000.0, 0.92);
thermoSystem.setMixingRule("classic");
thermoSystem.setMultiPhaseCheck(true);
thermoSystem.setMolarComposition(new double[] {0.034266, 0.005269, 0.039189, 0.700553, 0.091154,
thermoSystem.setMolarComposition(new double[] { 0.034266, 0.005269, 0.039189, 0.700553, 0.091154,
0.050908, 0.007751, 0.014665, 0.004249, 0.004878, 0.004541, 0.007189, 0.006904, 0.004355,
0.007658, 0.003861, 0.003301, 0.002624, 0.001857, 0.001320, 0.001426, 0.001164, 0.000916});
0.007658, 0.003861, 0.003301, 0.002624, 0.001857, 0.001320, 0.001426, 0.001164, 0.000916 });
// thermoSystem.prettyPrint();

Stream feedStream = new Stream("feed stream", thermoSystem);
feedStream.setFlowRate(604094, "kg/hr");
feedStream.setTemperature(25.5, "C");
feedStream.setPressure(26.0, "bara");

neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator seprator1stStage =
new neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator(
"1st stage separator", feedStream);
neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator seprator1stStage = new neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator(
"1st stage separator", feedStream);

ThrottlingValve valve1 = new ThrottlingValve("valve1", seprator1stStage.getLiquidOutStream());
valve1.setOutletPressure(19.0);

Heater oilHeater = new Heater("oil heater", valve1.getOutletStream());
oilHeater.setOutTemperature(359.0);

neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator seprator2ndStage =
new neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator(
"2nd stage separator", oilHeater.getOutletStream());
neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator seprator2ndStage = new neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator(
"2nd stage separator", oilHeater.getOutletStream());

ThrottlingValve valve2 = new ThrottlingValve("valve2", seprator2ndStage.getLiquidOutStream());
valve2.setOutletPressure(2.7);

StreamInterface recircstream1 = valve2.getOutletStream().clone("oilRecirc1");
recircstream1.setFlowRate(1e-6, "kg/hr");

neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator seprator3rdStage =
new neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator(
"3rd stage separator");
neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator seprator3rdStage = new neqsim.processSimulation.processEquipment.separator.ThreePhaseSeparator(
"3rd stage separator");
seprator3rdStage.addStream(valve2.getOutletStream());
seprator3rdStage.addStream(recircstream1);

ThrottlingValve pipeloss1st =
new ThrottlingValve("pipeloss1st", seprator3rdStage.getGasOutStream());
ThrottlingValve pipeloss1st = new ThrottlingValve("pipeloss1st", seprator3rdStage.getGasOutStream());
pipeloss1st.setOutletPressure(2.7 - 0.03);

Heater coolerLP = new Heater("cooler LP", pipeloss1st.getOutletStream());
Expand All @@ -102,8 +98,7 @@ public void runProcess() throws InterruptedException {
recycle1.addStream(valveLP1.getOutletStream());
recycle1.setOutletStream(recircstream1);

neqsim.processSimulation.processSystem.ProcessSystem operations =
new neqsim.processSimulation.processSystem.ProcessSystem();
neqsim.processSimulation.processSystem.ProcessSystem operations = new neqsim.processSimulation.processSystem.ProcessSystem();
operations.add(feedStream);
operations.add(seprator1stStage);
operations.add(valve1);
Expand All @@ -121,7 +116,7 @@ public void runProcess() throws InterruptedException {

operations.run();

assertEquals(17105.52983567356, seprator3rdStage.getGasOutStream().getFlowRate("kg/hr"), 1.1);
assertEquals(17105.52983567356, seprator3rdStage.getGasOutStream().getFlowRate("kg/hr"), 10.1);

assertEquals(seprator3rdStage.getGasOutStream().getFlowRate("kg/hr"),
coolerLP.getOutletStream().getFlowRate("kg/hr"), 1e-4);
Expand Down Expand Up @@ -161,9 +156,8 @@ public void runAntiSurgeProcess() throws InterruptedException {
gascompressor.run();

double fluidh = gascompressor.getPolytropicFluidHead();
neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator compchartgenerator =
new neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator(
gascompressor);
neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator compchartgenerator = new neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator(
gascompressor);
gascompressor.setCompressorChart(compchartgenerator.generateCompressorChart("mid range"));

Cooler gascooler = new Cooler("gas cooler");
Expand All @@ -177,7 +171,7 @@ public void runAntiSurgeProcess() throws InterruptedException {

Splitter gassplitter = new Splitter("gas splitter");
gassplitter.setInletStream(gassep.getGasOutStream());
gassplitter.setFlowRates(new double[] {7.0, 1.2}, "MSm3/day");
gassplitter.setFlowRates(new double[] { 7.0, 1.2 }, "MSm3/day");
gassplitter.run();

ThrottlingValve antisurgevalve = new ThrottlingValve("gas valve");
Expand All @@ -188,15 +182,13 @@ public void runAntiSurgeProcess() throws InterruptedException {
Recycle recycl = new Recycle("rec");
recycl.addStream(antisurgevalve.getOutletStream());
recycl.setOutletStream(recyclegasstream);
recycl.setFlowAccuracy(1e-20);
recycl.run();

Calculator antisurgeCalculator = new Calculator("anti surge calculator");
antisurgeCalculator.addInputVariable(gascompressor);
antisurgeCalculator.setOutputVariable(gassplitter);

neqsim.processSimulation.processSystem.ProcessSystem operations =
new neqsim.processSimulation.processSystem.ProcessSystem();
neqsim.processSimulation.processSystem.ProcessSystem operations = new neqsim.processSimulation.processSystem.ProcessSystem();
operations.add(gas_from_separator);
operations.add(recyclegasstream);
operations.add(gasmixer);
Expand All @@ -213,38 +205,39 @@ public void runAntiSurgeProcess() throws InterruptedException {
// gascompressor.getCompressorChart().setUseCompressorChart(false);

operations.run();
assertEquals(6.9999999, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-4);
assertEquals(1e-6, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-4);
assertEquals(6.9999999, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-2);
assertEquals(0.0, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-2);
assertEquals(4009.59769517, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-4);
assertEquals(90.91657683, gascompressor.getOutletPressure(), 1e-4);
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1);
assertEquals(90.91657683, gascompressor.getOutletPressure(), 1e-1);

gas_from_separator.setFlowRate(2.0, "MSm3/day");
operations.run();
// assertEquals(4.00961638, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-4);
// assertEquals(4.00961638,
// gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-4);
assertEquals(2.005737385700, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-2);
assertEquals(4157.46978573787, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-1);
assertEquals(4157.470818, gascompressor.getInletStream().getFlowRate("m3/hr"), 1e-2);
assertEquals(109.8098956, gascompressor.getOutletPressure(), 1e-2);
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1);
assertEquals(4157.470818, gascompressor.getInletStream().getFlowRate("m3/hr"), 10);
assertEquals(109.8098956, gascompressor.getOutletPressure(), 1e-1);

gas_from_separator.setFlowRate(8.0, "MSm3/day");
operations.run();
assertEquals(1.0000000000014376E-6, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"),
1e-4);
assertEquals(8.000000000000004, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-4);
1e-1);
assertEquals(8.000000000000004, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-2);
assertEquals(3914.332053456, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-4);
assertEquals(82.7494476493, gascompressor.getOutletPressure(), 1e-4);
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 10);
assertEquals(82.7494476493, gascompressor.getOutletPressure(), 1e-1);

gas_from_separator.setFlowRate(0.5, "MSm3/day");

operations.run();
assertEquals(5.70145187, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-4);
assertEquals(0.50010559709, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-4);
assertEquals(5.70145187, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-2);
assertEquals(0.50010559709, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 5e-2);
assertEquals(4159.042541, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-4);
assertEquals(112.0488937, gascompressor.getOutletPressure(), 1e-4);
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 10);
assertEquals(112.0488937, gascompressor.getOutletPressure(), 1);
}

@Test
Expand Down Expand Up @@ -286,7 +279,7 @@ public void runAntiSurgeProcess2() throws InterruptedException {

Splitter gassplitter = new Splitter("gas splitter");
gassplitter.setInletStream(gassep.getGasOutStream());
gassplitter.setFlowRates(new double[] {7.0, 1.2}, "MSm3/day");
gassplitter.setFlowRates(new double[] { 7.0, 1.2 }, "MSm3/day");

ThrottlingValve antisurgevalve = new ThrottlingValve("gas valve");
antisurgevalve.setInletStream(gassplitter.getSplitStream(1));
Expand All @@ -295,10 +288,9 @@ public void runAntiSurgeProcess2() throws InterruptedException {
Recycle recycl = new Recycle("rec");
recycl.addStream(antisurgevalve.getOutletStream());
recycl.setOutletStream(recyclegasstream);
recycl.setFlowAccuracy(1e-15);
recycl.setFlowAccuracy(1e-3);

neqsim.processSimulation.processSystem.ProcessSystem operations =
new neqsim.processSimulation.processSystem.ProcessSystem();
neqsim.processSimulation.processSystem.ProcessSystem operations = new neqsim.processSimulation.processSystem.ProcessSystem();
operations.add(gas_from_separator);
operations.add(recyclegasstream);
operations.add(gasmixer);
Expand All @@ -314,9 +306,8 @@ public void runAntiSurgeProcess2() throws InterruptedException {
double fluidh = gascompressor.getPolytropicFluidHead();
double flowratetocompressor = gascompressor.getInletStream().getFlowRate("MSm3/day");

neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator compchartgenerator =
new neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator(
gascompressor);
neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator compchartgenerator = new neqsim.processSimulation.processEquipment.compressor.CompressorChartGenerator(
gascompressor);
gascompressor.setCompressorChart(compchartgenerator.generateCompressorChart("mid range"));
gascompressor.setOutletPressure(90.0);
gascompressor.getCompressorChart().setUseCompressorChart(false);
Expand All @@ -329,40 +320,39 @@ public void runAntiSurgeProcess2() throws InterruptedException {

operations.run();
assertEquals(7.00019789, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-2);
assertEquals(0.001732061306, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-4);
assertEquals(0.0, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-1);
assertEquals(4685.038961, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-2);
assertEquals(5176.97051519596, gascompressor.getInletStream().getFlowRate("m3/hr"), 10);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-4);
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 10);
assertEquals(5176.97051519596, gascompressor.getInletStream().getFlowRate("m3/hr"), 50);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-1);

gas_from_separator.setFlowRate(1.0, "MSm3/day");
operations.run();
double flow = gasmixer.getOutletStream().getFlowRate("MSm3/day");
assertEquals(5.33483946, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-2);
assertEquals(1.0, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-4);
assertEquals(1.0, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-2);
assertEquals(4685.0389615, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-2);
assertEquals(4684.996901, gascompressor.getInletStream().getFlowRate("m3/hr"), 1e-1);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-4);

.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 10);
assertEquals(4684.996901, gascompressor.getInletStream().getFlowRate("m3/hr"), 10);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-1);

gas_from_separator.setFlowRate(9.0, "MSm3/day");
operations.run();
assertEquals(1.0224661428980936E-8, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"),
1e-2);
assertEquals(9.0, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-4);
assertEquals(9.0, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-2);
assertEquals(4685.0389615, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-2);
assertEquals(6656.10407208, gascompressor.getInletStream().getFlowRate("m3/hr"), 1e-2);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-4);
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 10);
assertEquals(6656.10407208, gascompressor.getInletStream().getFlowRate("m3/hr"), 10);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-2);

gas_from_separator.setFlowRate(5.5, "MSm3/day");
operations.run();
assertEquals(0.834839487572494, gassplitter.getSplitStream(1).getFlowRate("MSm3/day"), 1e-2);
assertEquals(5.5, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-4);
assertEquals(5.5, gassplitter.getSplitStream(0).getFlowRate("MSm3/day"), 1e-2);
assertEquals(4685.0389615, gascompressor.getCompressorChart().getSurgeCurve()
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 1e-2);
assertEquals(4685.038986, gascompressor.getInletStream().getFlowRate("m3/hr"), 1);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-4);
.getSurgeFlow(gascompressor.getPolytropicFluidHead()), 10);
assertEquals(4685.038986, gascompressor.getInletStream().getFlowRate("m3/hr"), 10);
assertEquals(90.0, gascompressor.getOutletPressure(), 1e-2);
}
}