Process Modeling Using HYSYS

Gas Gathering

Gas Gathering

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Process Modeling Using HYSYS

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.

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.

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

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Process Modeling Using HYSYS

Gas Gathering

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.
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.
Branch Segment

Length
Elevation
Elevation Change
meters (feet) meters (feet) meters (feet)

GasWell 1
Branch 1

Branch 2

639 (2095)

150 (500)

645 (2110)

125 (410)

636.5 (2089) -6.5 (-21)

100 (325)

637 (2090)

GasWell 2
1

200 (665)

637 (2090)

23 (75)
635.5 (2085)

160 (525)

648 (2125)

12.5 (40)

100 (325)

634 (2080)

-14 (-45)

205 (670)

633 (2077)

-1 (-3)

Branch 4 Branch 1 & 2

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0.5 (1)
614 (2015)

GasWell 3
Branch 3

6 (15)

637 (2090)

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Process Modeling Using HYSYS

Gas Gathering

355 (1165)

633 (2077)

GasWell 4

-4 (-13)
632.5 (2075)

Branch 5 1

180 (590)

625 (2050)

-7.5 (-25)

165 (540)

617 (2025)

-8 (-25)

Branch 6

Branch 7

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Branch 3 & 4
1

633 (2077)
300 (985)

617 (2025)

Branch 5 & 6
1

-16 (-52)
617 (2025)

340 (1115)

604 (1980)

-13 (-45)

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Process Modeling Using HYSYS

Gas Gathering

Process Overview

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Process Modeling Using HYSYS

Gas Gathering

Building the Simulation

The gas field will be modeled 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, N 2 , H 2
S, CO 2 , C 1 , C 2 , C 3 , i-C 4 , n-C 4 , i-C 5 , n-C 5 , C 6 , C 7 +*, H 2 0,
NBP[0]92*, NBP[0]171*, NBP[0]243*, NBP[0]322*, NBP[0]432*.
If you are using Field units,
the oil components will have
different names,
corresponding to the
different NBP.

The four streams should have the following values:

GasWell 1

GasWell 2 GasWell 3 GasWell 4

Temperature C (F)

40 (105)

45 (115)

Pressure kPa (psia)

4135 (600)

3450 (500) <empty>

Flow kgmole/h (lbmole/hr) 425 (935)

375 (825)

45 (115)

35 (95)
<empty>

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.
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.

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Process Modeling Using HYSYS

Gas Gathering

Adding the first Pipe Segment

1. Double-click the Pipe Segment icon.
Pipe Segment
icon

Connections Page
On the Connections page, the Inlet (Feed), Product, and Outlet
(Energy) stream connections are made.
2. Complete the Connections page as shown below:

Parameters Page

For single-phase
streams, the Darcy
equation is used for
pressure drop
predictions.

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
Tulsa99
For all of the pipes in this example, use the Beggs and Brill correlation
for two-phase flow.

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Process Modeling Using HYSYS

Gas Gathering

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.
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
have an Elevation of 0.
Positive elevation
indicates that the outlet
is higher than the inlet.

In this cell...

Enter...

Fitting/Pipe

Pipe

Length

150 m (500 ft)

Elevation Change

6 m (15 ft)

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

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.
HYSYS contains a
database for three pipe
schedules, 40, 80, and
160.

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

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)

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

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Process Modeling Using HYSYS

Gas Gathering

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.
Heat Transfer Coefficient Estimation. The overall HTC can
be found from its component parts.
o Inside Film Convection
o Outside Conduction/Convection
o Conduction through Insulation
For all pipes in this simulation, use the Estimate HTC method.
9. On the Rating page, click on Heat Transfer.

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Process Modeling Using HYSYS

Gas Gathering

10. Switch to the Overall HTC radio button, and enter an Ambient
Temperature of 5C (40F)
11. Switch to the Estimate HTC page, and complete it as follows:

What is the outlet pressure of Branch 1? _______________________________

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Process Modeling Using HYSYS

Gas Gathering

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

Remember for all pipes

in this example, use
Schedule 40, an Ambient
Temperature of 5C and
do not estimate the HTC
for Insulation.

Length

200 m (655 ft)

Elevation

23 m (75 ft)

Nominal Diameter

101.6 mm (4 in)
Schedule 40

Heat Transfer
Estimate the Inner, Outer and Pipe 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

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100 m (325 ft)

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Process Modeling Using HYSYS

Gas Gathering

Elevation

-14 m (-45 ft)

Nominal Diameter

76.2 mm (3 in)

Segment 3
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

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Process Modeling Using HYSYS

In this cell...

Gas Gathering

Enter...

Connections
Name

Branch 5

Inlet

GasWell 4

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? _____________________________________________

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Process Modeling Using HYSYS

Gas Gathering

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)

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? _____________________________________________

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Process Modeling Using HYSYS

Gas Gathering

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

Optional

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 that 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
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Process Modeling Using HYSYS

Gas Gathering

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

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
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Process Modeling Using HYSYS

Gas Gathering

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 38C
(100F) 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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Gas Gathering

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