Gas Gathering 1

Gas Gathering

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© 2003 AspenTech. All Rights Reserved.
EA1031.31.05
06 Gas Gathering.pdf
2 Gas Gathering

Workshop
In this example, a gas gathering system located on varied terrain is
simulated using the steady state capabilities of HYSYS. The following
figure shows the physical configuration of this system superimposed on
a topographic map. The system consists of four wells distributed over an
area of approximately 2.0 square km, connected to a gas plant via a
network of pipelines.

Figure 1

The gas in this case is varied, both sour and sweet gas are being
combined in the pipeline, as well as a gas condensate mixture. A Mixer
combines all of the incoming gas streams from the outlying wells into
one common header. Flowlines extending from this central site to each
of the individual wells are modelled in HYSYS using the Pipe Segment
operation. Since the plant is located in an area with mixed terrain, the
elevation changes, must be accounted for in the Pipe Segments.

Additional Mixer operations are used to model mixing points where

flows from remote wells are combined in common lines.

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Learning Objectives
Once you have completed this module, you will be able to use the Pipe
Segment in HYSYS to model pipelines.

Prerequisites
Before beginning this module you need to know how to add streams and
unit operations.

Process Overview
Pipe Diameters for each of the branches are:

Pipe Branch Diameter

Branch 1 76.2 mm (3")
Branch 2 101.6 mm (4")
Branch 3 76.2 mm (3")
Branch 4 101.6 mm (4")
Branch 5 76.2 mm (3")
Branch 6 152 mm (6")
Branch 7 152 mm (6")

Schedule 40 steel pipe is used throughout and all branches are buried at
a depth of 1 m (3 ft). All pipes are uninsulated.

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Elevation data for each of the branches are provided in the following
table. Branches that traverse undulating terrain have been subdivided
into a number of segments with elevation points assigned at locations
where there is a significant slope change. Such locations in the network
are labeled on the schematic diagram with the elevation value in italics.

Elevation
Length Elevation
Branch Segment Change
meters (feet) meters (feet)
meters (feet)
Branch 1 GasWell 1 639 (2095)
1 150 (500) 645 (2110) 6 (15)
2 125 (410) 636.5 (2089) -6.5 (-21)
3 100 (325) 637 (2090) 0.5 (1)
Branch 2 GasWell 2 614 (2015)
1 200 (665) 637 (2090) 23 (75)
Branch 3 GasWell 3 635.5 (2085)
1 160 (525) 648 (2125) 12.5 (40)
2 100 (325) 634 (2080) -14 (-45)
3 205 (670) 633 (2077) -1 (-3)
Branch 4 Branch 1 & 2 637 (2090)
1 355 (1165) 633 (2077) -4 (-13)
Branch 5 GasWell 4 632.5 (2075)
1 180 (590) 625 (2050) -7.5 (-25)
2 165 (540) 617 (2025) -8 (-25)
Branch 6 Branch 3 & 4 633 (2077)
1 300 (985) 617 (2025) -16 (-52)
Branch 7 Branch 5 & 6 617 (2025)
1 340 (1115) 604 (1980) -13 (-45)

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Process Overview
6 Gas Gathering

Building the Simulation

The gas field will be modelled using the Peng Robinson property
package. The fluid package needs to contain the components from the
Getting Started module as well as the oil components from the Gas
Chromatograph module.

Rather than adding the components and the oil again, open the case
from the Oil Characterization module (containing the four Gas Well
streams).

The following components should appear in the fluid package, N2, H2S,
CO2, C1, C2, C3, i-C4, n-C4, i-C5, n-C5, C6, C7+*, H20, NBP[0]92*,
NBP[0]171*, NBP[0]243*, NBP[0]322*, NBP[0]432*.

If you are using Field units, The four streams should have the following values:
the oil components will have
different names, GasWell 1 GasWell 2 GasWell 3 GasWell 4
corresponding to the
different NBP. Temperature °C (°F) 40 (105) 45 (115) 45 (115) 35 (95)
Pressure kPa (psia) 4135 (600) 3450 (500) <empty> <empty>
Flow kgmole/h (lbmole/hr) 425 (935) 375 (825) 575 (1270) 545 (1200)

Adding the Pipe Segments

The pipe segment is used to simulate a wide variety of piping situations
ranging from single/multiphase plant piping with rigorous heat transfer
estimation, to large capacity looped pipeline problems. It offers the
common pressure drop correlations developed by Gregory, Aziz, and
Mandhane, and Beggs and Brill. A third option, OLGAS, is also available
as a gradient method. In addition there are a large number of specialty
pressure drop correlations available. Consult the on-line help and the
manual for more information on these methods. Four levels of
complexity in heat transfer estimation allow you to find a solution as
rigorously as required while allowing for quick generalized solutions to
well-known problems.

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The pipe segment offers three calculation modes: Pressure Drop, Flow,
and Length; the appropriate mode will automatically be selected
depending on the information supplied. In order to solve the pipe, you
must supply enough information to completely define both the material
balance and energy balance.

In this simulation, we will be using seven individual pipe segment

operations in the gathering system. In addition, each Pipe Operation
may contain multiple segments to represent the various elevation rises
and drops.

Adding the first Pipe Segment

1. Double-click on the Pipe Segment icon.

Pipe Segment icon Connections page

On the Connections page, the Feed, Product and Energy stream
connections are made.

2. Complete the Connections page as shown below:

Figure 2

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Parameters page
On this page, you can select the gradient method which will be used for
two-phase (VL) flow calculations. The options are:

• Aziz, Govier & Fogarasi

• Baxendell & Thomas
• Beggs & Brill
• Duns & Ros
• Gregory, Aziz, Mandhane
• Hagedorn & Brown
• HTFS, Liquid Slip
• HTFS, Homogeneous Flow
• OLGAS2000_2P
• OLGAS2000_3P
• Orkiszewski
• Poettman & Carpenter
• Tacite Hydrodynamic Module
For single phase streams,
• Tulsa99
the Darcy equation is used
for pressure drop For all of the pipes in this example, use the Beggs and Brill correlation
predictions. for two-phase flow.

The pressure drop for the pipe can be supplied on the Parameters page.
In this example, it will be left empty and calculated.

Rating tab

Sizing page
On the Sizing page, you construct the length-elevation profile for the
Pipe Segment. Each pipe section and fitting is labeled as a segment. To
fully define the pipe sections segments, you must also specify pipe
schedule, diameters, pipe material and a number of increments.

The first pipe, Branch 1 is broken into three segments.

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3. Add the first segment to the pipe unit operation by clicking the
Append Segment button. Specify the following information for the
segment.

Horizontal pipe sections In this cell... Enter...

have an Elevation of 0.
Fitting/Pipe Pipe
Positive elevation indicates
that the outlet is higher than Length 150 m (500 ft)
the inlet. Elevation Change 6 m (15 ft)

4. To specify the diameter, click the View Segment button.

HYSYS contains a database
for three pipe schedules, 40,
80 and 160.
5. Select Schedule 40 as the Pipe Schedule.
6. From the Available Nominal Diameters group, select 76.20 mm (3
inch) diameter pipe and click the Specify button. The Outer and
Inner Diameter will be calculated by HYSYS.
7. Use the default Pipe Material, Mild Steel and the default Roughness,
4.572e-5 m (0.0018 inch).
8. Two more segments are needed to complete the branch.

In this cell... Enter... Enter...

Segment 2 3
Fitting/Pipe Pipe Pipe
Length 125 m (410 ft) 100 m (325 ft)
Elevation -6.5 m (-21 ft) 0.5 m (1 ft)
Schedule 40 40
Nominal Diameter 76.2 mm (3 inch) 76.2 mm (3 inch)

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When all three segments have been added and defined, the view should
look like this:

Figure 3

The Pipe Segment is not yet able to solve because we have not specified
any information about the heat transfer properties of the pipe.

Heat Transfer page

On this page, you select the method that HYSYS will use for the heat
transfer calculations.

You have the option of specifying the heat transfer information By

Segment or Overall.

• By Segment. You specify the Ambient Temperature and HTC

(Heat Transfer Coefficient) for each segment that was created on
the Dimensions page.
• Overall. One of four heat transfer methods will be applied to the
whole pipe segment.
• Duty Method. If the Overall heat duty of the segment is known,
the energy balance can be calculated immediately. Each
increment is assumed to have the same heat loss.
• Stream Temperatures. If both inlet and outlet and ambient
temperatures are specified, a linear profile is assumed and the
overall heat duty can be calculated.
• Overall Heat Transfer Coefficient Specified. If the overall HTC
and Ambient Temperature are known, then rigorous heat transfer
calculations are performed on each increment of the pipe.

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• Heat Transfer Coefficient Estimation. The overall HTC can be

found from its component parts.
• Inside Film Convection
• Outside Conduction/Convection
• Conduction through Insulation

For all pipes in this simulation, use the Estimate HTC method.

9. Switch to the Overall HTC radio button, and enter an Ambient

Temperature of 5°C (40°F)
10. Switch to the Estimate HTC page, and complete it as follows:

Figure 4

What is the outlet pressure of Branch 1? _______________________________

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Completing the Simulation

Now add the remaining unit operations to your case.

1. Add two Pipe Segments with the following values:

In this cell... Enter...

Connections
Name Branch 2
Inlet GasWell 2
Outlet B2 Out
Energy B2-Q
Dimensions
Segment 1
Length 200 m (655 ft)
Elevation 23 m (75 ft)
Nominal Diameter 101.6 mm (4 in)
Remember for all pipes in
Schedule 40
this example, use Schedule
40, an Ambient Temperature Heat Transfer
of 5°C and do not estimate Estimate the Inner, Outer and Pipe
the HTC for Insulation. Wall HTC
5° Ambient temperature

In this cell... Enter...

Connections
Name Branch 3
Inlet GasWell 3
Outlet B3 Out
Energy B3-Q
Dimensions
Segment 1
Length 160 m (525 ft)
Elevation 12.5 m (40 ft)
Nominal Diameter 76.2 mm (3 in)
Segment 2
Length 100 m (325 ft)
Elevation -14 m (-45 ft)
Nominal Diameter 76.2 mm (3 in)
Segment 3

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In this cell... Enter...

Length 205 m (670 ft)
Elevation -1 m (-3 ft)
Nominal Diameter 76.2 mm (3 in)
Heat Transfer
Estimate the Inner, Outer and Pipe
Wall HTC

2. Add a Mixer with the following information:

In this cell... Enter...

Connections
Name Junction 1
Inlets B1 Out, B2 Out
Outlet J1 Out
Parameters
Pressure Assignment Set Outlet to Lowest Inlet

3. Add two Pipe Segments to your case with the values provided in the
following tables.

In this cell... Enter...

Connections
Name Branch 4
Inlet J1 Out
Outlet B4 Out
Energy B4-Q
Dimensions
Segment 1
Length 355 m (1165 ft)
Elevation -4 m (-13 ft)
Nominal Diameter 101.6 mm (4 in)
Heat Transfer
Estimate the Inner, Outer and Pipe
Wall HTC

In this cell... Enter...

Connections
Name Branch 5
Inlet GasWell 4

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In this cell... Enter...

Outlet B5 Out
Energy B5-Q
Dimensions
Segment 1
Length 180 m (590 ft)
Elevation -7.5 m (-25 ft)
Nominal Diameter 76.2 mm (3 in)
Segment 2
Length 165 m (540 ft)
Elevation -8 m (-25 ft)
Nominal Diameter 76.2 mm (3 in)
Heat Transfer
Estimate the Inner, Outer and Pipe
Wall HTC

4. Add a second Mixer to your case.

In this cell... Enter...

Connections
Name Junction 2
Inlets B3 Out, B4 Out
Outlet J2 Out
Parameters
Pressure Assignment Equalize All

What is the pressure of GasWell 3? _____________________________________

How was this calculated? _____________________________________________

5. Add a Pipe Segment to your case.

In this cell... Enter...

Connections
Name Branch 6
Inlet J2 Out
Outlet B6 Out
Energy B6-Q
Dimensions
Segment 1
Length 300 m (985 ft)

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In this cell... Enter...

Elevation -16 m (-52 ft)
Nominal Diameter 152.4 mm (6 in)
Heat Transfer
Estimate the Inner, Outer and Pipe
Wall HTC

6. Add a Mixer to the simulation.

In this cell... Enter...

Connections
Name Junction 3
Inlets B5 Out, B6 Out
Outlet J3 Out
Parameters
Pressure Assignment Equalize All

What is the pressure of GasWell 4? _____________________________________

How was this calculated? _____________________________________________

7. Add another Pipe Segment to the simulation with the following

values:

In this cell... Enter...

Connections
Name Branch 7
Inlet J3 Out
Outlet B7 Out
Energy B7-Q
Dimensions
Segment 1
Length 340 m (1115 ft)
Elevation -13 m (-45 ft)
Nominal Diameter 152.4 mm (6 in)
Heat Transfer
Estimate the Inner, Outer and Pipe
Wall HTC

Save your case!

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Optional
Convert your case to a template
and save!

Analyzing the Results

If you saved your case as a template, close the template and open the
saved case.

The Profiles page on the Performance tab provides a summary table for
the segments which make up the Pipe Segment. The distance, elevation
and number of increments are displayed for each segment.

By clicking the View Profile button, you access the Pipe Profile view,
which consists of a Table tab and a Plot tab. The Table tab shows the
following information for each increment along the Pipe Segment.

• Length
• Elevation
• Pressure
• Temperature
• Heat Transferred
• Flow Regime
• Liquid Holdup
• Friction Gradient
• Static Gradient
• Accel Gradient
• Bulk Liquid and Vapour Reynolds Number
• Bulk Liquid and Vapour Velocity

The Plot tab graphically displays the profile data that is listed on the
Table tab.

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Open the property view for Branch 1 and examine the Table and Plots on
the Profiles page of the Performance tab.

Figure 5

Figure 6

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Exploring the Simulation

Exercise 1: Pipe Flow
The flow of gas being produced by GasWell 2 increases to about 1000
kgmole/h (2200 lbmole/hr). Can the existing pipeline handle this
increased flow? If not, what pipe is limiting the flow in the system? What
size will be required for this branch? Do any other parts of the pipeline
need to be changed?

Challenge
You instruct your summer student, Peter Reynolds to go out to the field
and measure the temperature and pressure of the gas that is being
delivered to the Gas Plant. He reports that the temperature is 38°C
(100°F) and the pressure is 7457 kPa (1080 psia). Using your HYSYS
simulator, what do you find the pressure of each of the Gas Wells to be?

Hint: you will have to make some changes to the simulation in order for
it to solve completely.

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