Build a Gas Gathering System

Workshop
Files can be found in folder: 10_GasGathering

Objective
In this workshop, you will use the Pipe Segment in Aspen HYSYS to create simple
hydraulic piping models. You will also learn how to use the Flow Assurance options in
the Pipe Segment to study flow viability and operability for a variety of process conditions.

In this example, a gas/liquid hydrocarbon gathering system located on varied terrain is

simulated using the steady state capabilities of Aspen 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 by a network of pipelines.

The gas in this case is varied; both sour and sweet gases are being combined in the pipeline,
as well as a gas condensate mixture. One well even includes some produced water. A
variety of mixers and piping manifolds combine all of the incoming streams from the
outlying wells into one common header. Flow lines extending from this central site to each
of the individual wells are modelled in Aspen 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 Segment operations.

19 - 1
Un-insulated schedule 40 steel piping is used throughout, and all branches are buried at a
depth of approximately 1 m (3.2 ft). Mixer operations are used to model mixing points
where flows from remote wells are combined in common lines.

This workshop includes the following tasks:

• Task 1 – Add the First Branch

• Task 2 – Complete the Piping Network
• Task 3 – Perform Flow Assurance Studies

Task 1 – Add the First Branch

The Fluid Package details and material stream conditions for the four gas wells have
already been defined in a separate HYSYS model; so much of the initial information has
already been supplied for your pipeline model.

1. To begin the workshop, open the case 10-GasGatheringStarter.hsc. It should be

available in your course files folder provided by your instructor.

The component list should be comprised of the standard Assay Management components
as the GasWell4 material stream is defined using a Petroleum Assay. The other inlet
streams should be characterized with defined mole fraction compositions. The Peng-
Robinson equation of state is defined as the Property Package.

2. View the Simulation Environment and ensure that the four feed streams have
the following specifications:

GasWell1 GasWell2 GasWell3 GasWell4

Temperature °C (°F) 40.6 (105) 46.1 (115) 46.1 (115) 32.2 (90)

Pressure kPa (psia) 4137 (600) 3792 (550) <empty> <empty>

Flow kgmole/h (lbmol/hr) 424.1 (935) 374.2 (825) 576.1 (1270) 546.6 (1205)

In this simulation, seven individual Pipe Segment unit operations will be used to represent
the gathering system pipelines. In addition, each Pipe Segment operation may contain
multiple segments to represent the various elevation changes across the pipeline
environment.

3. Add a Pipe Segment operation by double clicking on the appropriate icon on the
Model Palette:

19 - 2
 4. Complete the Design | Connections page as shown in the following figure:

On the Design | Parameters page, you can select the correlation(s) that will be used to
determine pressure drop for the multi-phase flow calculations. If desired, separate
correlations can be used for horizontal, inclined and vertical flow. Unless otherwise
specified, the default method developed by Beggs and Brill (1979) is used; however your
piping network will make use of a more-recently developed method, the Tulsa Unified
Model.

Note: For single phase streams, the Darcy equation is used for pressure drop calculations.

5. Select the Design | Parameters page and select the Tulsa Unified Model (2-
Phase) for the Horizontal, Vertical, and Inclined Pipe Flow Correlations.

19 - 3
Additionally, a user defined pressure drop for the pipe segment can be supplied on the
Design | Parameters page. In this example, it will be left empty as it will be calculated by
the selected pressure drop correlation.

On the Rating | Sizing page, you can construct the full elevation profile for the Pipe
Segment operation. Each pipe section and fitting is considered to be a segment. In addition
to the elevation, you must also specify pipe schedule, diameter, pipe material, and a number
of calculation increments in order to fully define a pipe section.

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

6. Select the Rating | Sizing page of the Branch 1 Pipe Segment property view and
add the first segment to the pipe unit operation by clicking the Append Segment
button. Specify the following information for the segment:

In this cell... Enter...

Fitting/Pipe Pipe

Length 152 m (500 ft)

Elevation Change 6 m (20 ft)

Note: Horizontal pipe sections have an Elevation Change of 0. A positive elevation change
indicates that the outlet is higher than the inlet (upward flow) while a negative elevation
change indicates that the outlet is lower than in the inlet (downward flow).

7. Click the View Segment button and select Schedule 40 as the Pipe Schedule.

19 - 4
Note: The Aspen HYSYS Pipe Segment contains a database for several pipe schedules.

8. From the Nominal Diameters dropdown menu, select 80 mm (3 inch) diameter

pipe. The Outer and Inner Diameters will be calculated based on the nominal size.
Keep the default pipe material and roughness.

9. Return to the Rating | Sizing page. Two more segments are needed to complete
the branch. Click the Append Segment button twice and enter the information
displayed in the table below:

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

Segment 2 3

Fitting/Pipe Pipe Pipe

Length 125 m (410 ft) 99 m (325 ft)

Elevation -6.4 m (-21 ft) 0.3 m (1 ft)

Schedule 40 40

Nominal Diameter 80 mm (3 inch) 80 mm (3 inch)

Once all three segments have been added and defined, the Pipe Segment will not yet be
able to solve because no heat transfer information has been specified yet for the pipe.

19 - 5
10. Open the Rating | Heat Transfer page of the Pipe Segment property view.

11. Activate the Estimate HTC radio button and complete the inputs as shown in the
following figure:

12. The Branch 1 Pipe Segment should be calculated. Save the file as 10-
Branch1.hsc

19 - 6
QUESTION: What is the outlet pressure of Branch 1? [Write your answer below]

Task 2 – Completing the Piping Network

The remaining Pipe Segments will now be added to the flowsheet to complete the pipeline
network.

13. Add two Pipe Segments to the flowsheet and use the following specifications, the
first one is called Branch 2 and the second one is called Branch 3.

In this cell… Enter…

Connections

Name Branch 2

Inlet GasWell2

Branch 3Outlet B2 Out

Energy B2-Q

Parameters

Pipe Flow Correlation (Horizontal, Tulsa Unified Model (2-phase)

Vertical, and Inclined)

Sizing

Segment 1

Length 200 m (65623 ft)

Elevation 23 m (75 ft)

Nominal Diameter 100 mm (4 in), Schedule 40

Heat Transfer

Estimate HTC
5°C (41°F) Ambient temperature
Include Pipe Wall, Inner HTC, and Outer HTC

19 - 7
 In this cell... Enter...
Connections
Name Branch 3
Inlet GasWell3
Outlet B3 Out
Energy B3-Q
Parameters
Pipe Flow Correlation (Horizontal, Tulsa Unified Model (3-phase)
Vertical, and Inclined)
Sizing
Segment 1
Length 160 m (525 ft)
Elevation 12.2 m (40 ft)
Nominal Diameter 80 mm (3 in), Schedule 40
Segment 2
Length 99 m (325 ft)
Elevation -14 m (-46 ft)
Nominal Diameter 80 mm (3 in), Schedule 40
Segment 3
Length 204 m (670 ft)
Elevation -0.9 m (-3 ft)
Nominal Diameter 80 mm (3 in), Schedule 40
Heat Transfer
Estimate HTC
5°C (41°F) Ambient temperature
Include Pipe Wall, Inner HTC, and Outer HTC

14. On the Rating | Sizing page of Branch 3, change the number of calculation
Increments from the default of 5 to 10 for each segment of the branch. This will
make it easier to calculate the three-phase flashes along the length of the line that
are required by the 3-phase Tulsa Unified Model.

19 - 8
Note: The flow from GasWell3 will be a three-phase fluid as there is some water present
along with the hydrocarbon gas and liquid. To properly accommodate this three-phase
flow, you should have used the 3-phase Tulsa Unified Model. For other lines that do not
have any water, the 2-phase version of the model will suffice.

QUESTION: Is Branch 3 able to calculate at this point? Why not? [Write your answer
below]

15. 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

19 - 9
16. Add a Pipe Segment downstream of Junction 1 with the specifications provided
in the following table:

In this cell... Enter...

Connections
Name Branch 4
Inlet J1 Out
Outlet B4 Out
Energy B4-Q
Parameters
Pipe Flow Correlation (Horizontal, Tulsa Unified Model (2-phase)
Vertical, and Inclined)
Sizing
Segment 1
Length 355 m (1165 ft)
Elevation -4 m (-13 ft)
Nominal Diameter 100 mm (4 in), Schedule 40
Heat Transfer
Estimate HTC
5°C (41°F) Ambient temperature
Include Pipe Wall, Inner HTC, and Outer HTC

17. Add a second Mixer to your flowsheet, and enter the following information:

In this cell... Enter...

Connections

Name Junction 2

Inlets B3 Out, B4 Out

Outlet J2 Out

Parameters

Pressure Assignment Equalize All

QUESTION: Was Branch 3 able to calculate after adding Junction 2? What is the
calculated pressure in GasWell3? [Write your answer below]

19 - 10
18. Add another Pipe Segment, using the following information:

In this cell... Enter...

Connections
Name Branch 5

Inlet J2 Out
Outlet B5 Out
Energy B5-Q

Parameters
Pipe Flow Correlation (Horizontal, Tulsa Unified Model (3-phase)
Vertical, and Inclined)

Sizing
Segment 1
Length 300 m (984 ft)

Elevation -16 m (-52 ft)

Nominal Diameter 150 mm (6 in), Schedule 40
Increments 10

Heat Transfer
Estimate HTC
5°C (41°F) Ambient temperature
Include Pipe Wall, Inner HTC, and Outer HTC

19. Tie-in the last well (GasWell4) with a Pipe Segment using the values provided in
the table below:

In this cell... Enter...

Connections
Name Branch 6
Inlet GasWell4
Outlet B6 Out
Energy B6-Q
Parameters
Pipe Flow Correlation (Horizontal, Tulsa Unified Model (2-phase)
Vertical, and Inclined)

19 - 11
 In this cell... Enter...
Sizing
Segment 1
Length 180 m (590 ft)
Elevation -7.6 m (-25 ft)
Nominal Diameter 80 mm (3 in), Schedule 40
Segment 2
Length 165 m (541 ft)
Elevation -8 m (-26 ft)
Nominal Diameter 80 mm (3 in), Schedule 40
Heat Transfer
Estimate HTC
5°C (41°F) Ambient temperature
Include Pipe Wall, Inner HTC, and Outer HTC

20. Add one final Mixer to the flowsheet:

In this cell... Enter...

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

QUESTION: What is the pressure of GasWell4? How was this calculated? [Write
your answer below]

21. Add the final Pipe Segment to the flowsheet using the table below:

In this cell... Enter...

Connections
Name Branch 7

Inlet J3 Out
Outlet B7 Out

19 - 12
 Energy B7-Q

Parameters
Pipe Flow Correlation (Horizontal, Tulsa Unified Model (3-phase)
Vertical, and Inclined)

Dimensions
Segment 1
Length 340 m (1115 ft)

Elevation -14 m (-46 ft)

Nominal Diameter 150 mm (6 in) Schedule 40
Heat Transfer

Estimate HTC
5°C (41°F) Ambient temperature
Include Pipe Wall, Inner HTC, and Outer HTC

22. Save your case as 10-GasGathering.hsc.

The Performance | Profiles page provides a summary table for all the segments that
comprise a given pipe. The distance, elevation, and number of increments are displayed
for each segment. By clicking the View Profile button, one can access the Pipe Profile view
which provides detailed information for each increment within the Pipe Segment.

23. On Branch 7, navigate to the Performance | Profiles page and click the View
Profile button.

QUESTION: What happens to the vapor velocity as we approach the exit of Branch
7? Why? [Write your answer below]

Task 3 – Perform Flow Assurance Studies

The HYSYS Pipe Segment features five powerful flow assurance calculation capabilities.
These calculations check the physical structures of the pipe itself versus the predicted wear
caused by the type of fluid being conveyed. This allows the process simulator to quickly
and easily judge the viability of a pipeline over time based on whatever fluid is being
modeled.

The particular flow assurance calculations that can be performed are as follows: hydrate
formation calculation, rate of corrosion due to CO2, erosional velocity, slug flow analysis,

19 - 13
and wax deposition. You will investigate a few of these flow assurance concerns on the
Branch 7 pipeline.

24. Viewing your flowsheet, double-click on the Branch 7 Pipe Segment.

25. Select the Flow Assurance tab.

26. Begin by checking the erosional velocity in the line so make sure you are viewing
the Flow Assurance | Erosion page. Keeping all the default settings, check the
Do Erosion Calc checkbox and calculations should begin.

19 - 14
QUESTION: Is the velocity of fluid in Branch 7 exceeding the erosional velocity?
[Write your answer below]

QUESTION: If so, what line size is needed to avoid exceeding the erosional velocity?
[Write your answer below]

27. Re-define the original line size used for Branch 7 (150 mm (6 inch), Schedule
40).

28. Move on to the Flow Assurance | Slug Analysis page to check Branch 7 for any
slug flow concerns.

29. Keep the default settings for the slug calculations and check the Do Slug
Calculations checkbox.

19 - 15
 30. Check the Status column to see if slug flow exists at any point along Branch 7.

QUESTION: Does your Branch 7 pipe segment appear to have slug flow concerns?
[Write your answer below]

QUESTION: If so, what is the slug velocity? [Write your answer below]

QUESTION: What appears to be the length of a slug at the inlet of the pipe? At the
outlet? [Write your answer below]

31. Save your case as 10-FlowAssurance.hsc.

19 - 16
Challenge Question
Field measurements suggest that the gas is being delivered to the Gas Plant (i.e. B7 Out
stream) at a temperature of 38°C (100°F) and a pressure of 3103 kPa (450 psia).

QUESTION: Can you make the flowsheet calculate in such a way that HYSYS back-
calculates the GasWell stream pressures after specifying the above temperature and
pressure at B7Out? [Write your answer below]

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

Recommended Reading
Knowledge Base Article 000029773
What does “increment dP > 10% of inlet” mean?

Knowledge Base Article 000029859

Are the velocities reported in the HYSYS pipe segment Actual or Superficial velocities?

Knowledge Base Article 000042748

What should I check if I am receiving notification of a negative pressure in the pipe
segment?

Knowledge Base Article 000042553

How is the liquid holdup defined in the Pipe Segment?

Knowledge Base Article 000029597

What criteria does the Pipe Segment use when checking for Choked Flow?

19 - 17
Notes:

19 - 18
Build a Gas Gathering System Solutions
Files can be found in folder: 10_GasGathering/Solutions

Task 1
QUESTION: What is the outlet pressure of Branch 1?

3889 kPa (564 psia)

Task 2
QUESTION: Is Branch 3 able to calculate at this point? Why not?

No, it is not. Considering the known parameters, the piping geometry and fluid flow rate
are known, however both the inlet and outlet pressure are unknown. One of these pressures
needs to be fixed before the Pipe Segment will calculate.

QUESTION: Was Branch 3 able to calculate after adding Junction 2? What is the
calculated pressure in GasWell3?

Yes. GasWell3 pressure is 4236 kPa (614.4 psia)

QUESTION: What is the pressure of GasWell4? How was this calculated?

The pressure of GasWell4 is 4104 kPa (595.3 psia). This pressure is back-calculated based
on the Equalize All pressure assignment around the Junction 3 Mixer. The GasWell3
stream pressure was calculated in the same way.

QUESTION: On Branch 7, navigate to the Performance | Profiles page and click the
View Profile button. What happens to the vapor velocity as we approach the exit of
Branch 7? Why?

The vapor velocity in Branch 7 increases as the fluid passes through the pipe. This is
because the volumetric flow rate of the vapor is increasing due to flashing as well as to
expansion as the static pressure decreases.

Task 3
QUESTION: Is the velocity of fluid in Branch 7 exceeding the erosional velocity?

Yes – along the entire length of the line.

19 - 19
QUESTION: If so, what line size is needed to avoid exceeding the erosional velocity?

Increasing to 200 mm (8 inch), Sch 40 pipe brings the fluid velocity below the erosional
velocity.

QUESTION: Does your Branch 7 pipe segment appear to have slug flow concerns?

Yes – along the full length of the line.

QUESTION: If so, what is the slug velocity?

Between 16.22 m/s (53.22 ft/s) and 17.17 m/s (56.34 ft/s)

QUESTION: What appears to be the length of a slug at the inlet of the pipe? At the
outlet?

Slug length at inlet: 29.34 m (96.26 ft)

Slug length at outlet: 50.45 m (165.5 ft)

19 - 20
Challenge Exercise
QUESTION: Can you make the flowsheet calculate in such a way that HYSYS back-
calculates the GasWell stream pressures after specifying the above temperature and
pressure at B7Out?

Since pressure is being fixed at the outlet of the network, all inlet pressures should be
removed. Then you should be able to enter the given temperature and pressure at B7 Out.
However, the network does not solve completely if the pressure of GasWell1 and GasWell2
are deleted in favor of specifying the B7 Out temperature and pressure.

Changing the pressure assignment in Junction 1 to Equalize All results in enthalpies around
the Junction 1 being over specified; however, this can be eliminated by deleting the
temperature of either GasWell1 or GasWell2. To avoid an arbitrary selection, an Adjust
operation can be used to establish a relationship between these two inlet stream
temperatures.

19 - 21