Optimize Pipeline Flow and Uptime with Pipe Flow Hydraulic Analysis in Aspen HYSYS

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1 Optimize Pipeline Flow and Uptime with Pipe Flow Hydraulic Analysis in Aspen HYSYS Anum Qassam, Product Management & Jennifer Dyment, Product Marketing March 20 th, 2018

Today s Presenters Anum Qassam Senior Product

Dyment Product Marketing Specialist, AspenTech

9 SOLUTION: Pipeline Hydraulic Insights with Intuitive Setup Bubble Mist Stratified POWERFUL Backed by the best library of physical properties ADVANCED Dynamic multiphase pipeline modeling INTEGRATED Same simulator for pipelines and equipment 2018 Aspen Technology, Inc. All rights reserved. 9

Model Fluid Flow from the Well-Head to the Transportation Pipelines HYSYS Hydraulics HYSYS Pipe w/ Flow Assurance Models Well Fluid Characterization using Aspen HYSYS Oil & Gas Feed Pipeline

10 Model Fluid Flow from the Well-Head to the Transportation Pipelines HYSYS Hydraulics HYSYS Pipe w/ Flow Assurance Models Well Fluid Characterization using Aspen HYSYS Oil & Gas Feed Pipeline Hydraulics Modeling with HYSYS Pipe Segment & HYSYS Hydraulics Oil & Gas Feed HYSYS Hydraulics w/ Flow Assurance Models HYSYS Hydraulics HYSYS Pipe w/ Flow Assurance Models Flow Assurance & Pipe Integrity with Hydrate, Wax, Erosion, and Slug analysis Transient Operation Modeling With HYSYS Hydraulics Dynamics Online & Offline Pipeline Modeling with Plant Data Calibration & Aspen OnLine Dynamics Aspen Online 2018 Aspen Technology, Inc. All rights reserved. 10

11 Model Fluid Flow from the Well-Head to the Transportation Pipelines HYSYS Hydraulics HYSYS Pipe w/ Flow Assurance Models Well Fluid Characterization using Aspen HYSYS Oil & Gas Feed Pipeline Hydraulics Modeling with HYSYS Pipe Segment & HYSYS Hydraulics Oil & Gas Feed HYSYS Hydraulics w/ Flow Assurance Models HYSYS Hydraulics HYSYS Pipe w/ Flow Assurance Models Flow Assurance & Pipe Integrity with Hydrate, Wax, Erosion, and Slug analysis Transient Operation Modeling With HYSYS Hydraulics Dynamics Online & Offline Pipeline Modeling with Plant Data Calibration & Aspen OnLine Dynamics Aspen Online 2018 Aspen Technology, Inc. All rights reserved. 11

indestructible. We who use computers know better.

13 What are you trying to do? Different assumptions can be made depending of the way the problem is formulated: Steady State Transient Isothermal Adiabatic Ideal Gas Compressible PVT Tables HEM Incompressible HNEM HFM 2018 Aspen Technology, Inc. All rights reserved. 13

14 What are you trying to do? Different assumptions can be made depending of the way the problem is formulated: Steady State Transient Isothermal Adiabatic Ideal Gas Compressible PVT Tables HEM Incompressible HNEM HFM There are many options to simulate piping, pipes or pipelines in AspenTech suite: HYSYS: Valves, Pipe Segment, Aspen Hydraulics, Compressible Gas Pipe Aspen Flare System Analyzer Aspen Plus Pipes, Pipelines Aspen Custom Modeler 2018 Aspen Technology, Inc. All rights reserved. 14

15 What are you trying to do? Different assumptions can be made depending of the way the problem is formulated: Steady State Transient Isothermal Adiabatic Ideal Gas Compressible PVT Tables HEM Incompressible HNEM HFM There are many options to simulate piping, pipes or pipelines in AspenTech suite: HYSYS: Valves, Pipe Segment, Aspen Hydraulics, Compressible Gas Pipe Aspen Flare System Analyzer Aspen Plus Pipes, Pipelines Aspen Custom Modeler The scope of this discussion will be Aspen HYSYS Hydraulics (and how it compares to HYSYS Pipe and HYSYS Gas Pipe) 2018 Aspen Technology, Inc. All rights reserved. 15

HYSYS Pipe Models Pipe Segment Easy configuration Rigorous heat transfer Applies for both single and multiphase flows Good option in dynamic for single phase flow Compressible Gas Pipe Only

17 HYSYS Pipe Models Pipe Segment Easy configuration Rigorous heat transfer Applies for both single and multiphase flows Good option in dynamic for single phase flow Compressible Gas Pipe Only applicable to single phase flow lines Aimed at dynamic simulation Possible option for safety Carefully assess the assumptions made on the properties Aspen Hydraulics Advanced Hydraulic modeling environment Handles single and multiphase flow both in steady state and dynamic Best option for Piping networks 2018 Aspen Technology, Inc. All rights reserved. 17

18 Aspen HYSYS Hydraulics for Pipe & Pipeline Network Modelling

19 Practical Solutions Required Simplification Required to Solve Problems This presentation provides a technical overview of pipeline network modelling using HYSYS Hydraulics Advantages Rigorously models pipe networks (e.g. flow splits based on hydraulics) Supports a variety of boundary node specifications (e.g. pressure-based flow distributions) Rigorous two-phase flow handling in both steady state and dynamics 2018 Aspen Technology, Inc. All rights reserved. 19

20 Practical Solutions Required Simplification Required to Solve Problems This presentation provides a technical overview of pipeline network modelling using HYSYS Hydraulics Advantages Rigorously models pipe networks (e.g. flow splits based on hydraulics) Supports a variety of boundary node specifications (e.g. pressure-based flow distributions) Rigorous two-phase flow handling in both steady state and dynamics Disadvantages Supports only COMThermo and Aspen Properties Limited unit operation models Dynamic modeling performance slower than standard HYSYS Dynamics 2018 Aspen Technology, Inc. All rights reserved. 20

Key Concept: Property package selection with HYSYS Hydraulics When planning to use Aspen Hydraulics, special attention is required when selecting a fluid package and associated property package.

Aspen HYSYS supports three groups of property packages: HYSYS, Aspen Properties, and COMThermo. Aspen Hydraulics only supports Aspen Properties or COMThermo property package groups.

If you have already characterized your fluid using the HYSYS fluid package with the Peng-Robinson or SRK property package, the fluid will be automatically mapped to the COMThermo fluid package and

22 Key Concept: Property package selection with HYSYS Hydraulics When planning to use Aspen Hydraulics, special attention is required when selecting a fluid package and associated property package. In this tutorial, a fluid package (Aspen Properties), property package (Peng-Robinson), and component list have already been added. Aspen HYSYS supports three groups of property packages: HYSYS, Aspen Properties, and COMThermo. Aspen Hydraulics only supports Aspen Properties or COMThermo property package groups. Aspen Properties is the recommended fluid package to use for hydraulic modeling because it provides the fastest performance. If you have already characterized your fluid using the HYSYS fluid package with the Peng-Robinson or SRK property package, the fluid will be automatically mapped to the COMThermo fluid package and Peng-Robinson or SRK property package, as appropriate. Component list Fluid package selection Currently, the only HYSYS property packages that are converted automatically to COMThermo are Peng-Robinson and SRK. If you choose a HYSYS property package that is neither of these (e.g. CPA), then the fluid will be mapped to the COMThermo Peng-Robinson property package for use within the Aspen Hydraulics Sub-Flowsheet. Property package selection 2018 Aspen Technology, Inc. All rights reserved. 22

Key Concept: Aspen Hydraulics Sub-flowsheet The Aspen Hydraulics unit operation is available only within Aspen HYSYS and it checks out an extra 13 tokens using the HYSYS Upstream token license.

This means that the fundamental equations used to model each unit operation in Hydraulics is different from the equations used to model the same unit operation in main HYSYS.

23 Key Concept: Aspen Hydraulics Sub-flowsheet The Aspen Hydraulics unit operation is available only within Aspen HYSYS and it checks out an extra 13 tokens using the HYSYS Upstream token license. All unit operation models within the hydraulics flowsheet are distinct and separate from models in Aspen HYSYS. This means that the fundamental equations used to model each unit operation in Hydraulics is different from the equations used to model the same unit operation in main HYSYS. Further, the models used in Hydraulics Steady State are different from the models used in Hydraulics Dynamics. This tutorial only discusses the models in Hydraulics Steady State. Ribbon buttons to navigate between flowsheets Aspen Hydraulics Steady State is an equation-oriented modeling environment, which means that the whole flowsheet solves together. This is in contrast to HYSYS, which solves unit operations sequentially, as soon as they are defined to zero degrees of freedom. There are many ways to work with sub-flowsheets in Aspen HYSYS. For this demonstration, you will primarily be working within the Hydraulics subflowsheet, so use the Go to Parent and Enter Subflowsheet buttons on the Flowsheet ribbon to navigate between the main flowsheet and any subflowsheets. You can also right click on the subflowsheet object and keep the flowsheet open in its own tab. Hydraulics Model Palette 2018 Aspen Technology, Inc. All rights reserved. 23

The Acceleration Pressure Drop (pressure drop due to velocity changes) is another key input to verify. The Static Head Contribution is relevant for vertical piping.

24 Key Concept: Specifying the Pipe Model When specifying the pipe model, attention should be paid to the assumptions in the model. Reducing assumptions will reduce the solve time, increasing the erformance. First-and-foremost, attention should be paid to the Calculation Method. The Acceleration Pressure Drop (pressure drop due to velocity changes) is another key input to verify. The Static Head Contribution is relevant for vertical piping. Finally, the Friction Factor Method affects the way that the friction factor (used by the Calculation Method ) is calculated. It usually has a minor effect on the dp dl term. dp dl = ρ mg sinθ + Gravitational pressure drop dp + ρ dl m v dv f dl Frictional pressure drop Acc l pressure drop 2018 Aspen Technology, Inc. All rights reserved. 24

2018 Courses AIChE Annual Meeting Orlando, FL Product Training Class 2018 Dates Aspen HYSYS EHY101 Aspen HYSYS: Process Modeling Apr 16 to 18 Apr 30 to May 2 Go to website EHY105: Refining: Ops &

29 2018 Courses AIChE Annual Meeting Orlando, FL Product Training Class 2018 Dates Aspen HYSYS EHY101 Aspen HYSYS: Process Modeling Apr 16 to 18 Apr 30 to May 2 Go to website EHY105: Refining: Ops & Troubleshooting Crude Unit & Preheat Train EHY106: Optimize From the Wellhead to a Gas Processing Facility EHY107: Process Safety with BLOWDOWN Tech and PSV Sizing EHY202 Aspen HYSYS: Advanced Process Modeling Topics EHY250: Rapid Depressurization Safety Limits for Design and Rating Apr 27 (1-day) Apr 27 (1-day) Apr 27 (1-day) Apr 19 to 20 May 3 to 4 Apr 27 (1-day) HYSYS/Plus EHY252/EAP252: Pressure Relief Analysis Using HYSYS and Plus Apr 27 (1-day) Aspen Plus EAP101 Aspen Plus: Process Modeling Apr 16 to 18 EAP150: Rigorous Design and Rating of Distillation Columns EAP151: Monitor Distill Column Ops to Predict and Prevent Failures Apr 27 (1-day) Apr 27 (1-day) EAP201 Aspen Plus: Physical Properties for Process Engineers Apr 19 to 20 EAP2911 Solids Modeling Using Aspen Plus Apr 26 to 27 Sim Workbook EHY121: EHY121 Building MS Excel User Interfaces for HYSYS Apr 27 (1-day) Flare System EHY2511: Flare Network Design and Rating Apr 26 to 27 Orlando, FL 2018 Aspen Technology, Inc. All rights reserved. 29

31 Additional Resources White Paper: Multiphase Pipe Flow Modeling in Aspen HYSYS White Paper: An Integrated Approach to Pipeline Modeling in a Gathering and Production System White Paper: A Study of Terrain- Induced Slugging in Pipelines Aspen HYSYS Online Trial Application Example: Pigging Operations using Aspen HYSYS Hydraulics Process Ecology Reduces Capital Costs and Prevents Downtime by Using the Aspen HYSYS Family 2018 Aspen Technology, Inc. All rights reserved. 31

Upstream Offering with Aspen HYSYS Well Fluid

Assurance Facility Development Oil & Gas Feed Aspen

Hydrates, Wax, Erosion Methanol, Mercury, Corrosion,

GAP Prosper PVTSim PVTP Multiflash PIPESIM, OLGA

33 Upstream Offering with Aspen HYSYS Well Fluid Characterization Pipeline Hydraulics Modeling Flow Assurance Facility Development Oil & Gas Feed Aspen Hydraulics Steady State Dynamics TUFFP Correlations Hydrates, Wax, Erosion Methanol, Mercury, Corrosion, Slugging Conceptual Design Builder Neotec Black Oil GAP Prosper PVTSim PVTP Multiflash PIPESIM, OLGA 2015 OLGA Aspen Technology, Inc. All rights reserved.

34 An Aside on Single Phase Flow

35 Single Phase Fundamentals: Incompressible Flow Key concern: Is the incompressible flow assumption valid (i.e. negligible change in density across pipe)? If incompressible, the Darcy-Weisbach equation is well-accepted for modelling fluid flow in pipes Source: Wikipedia 2018 Aspen Technology, Inc. All rights reserved. 35

36 Single Phase Fundamentals: Compressible Flow When treating gas as compressible it is important to assess: What information do I have, and what am I trying to calculate? Do I have a network system or a single pipe system? How important are heat transfer effects on my system? Recommended reading: Aspen Technology, Inc. All rights reserved. 36

37 Into the models HYSYS Pipe Segment Darcy-Weisbach assumed for single phase flow, pressure drop due to acceleration is neglected 2-Phase flow models are solving for the pressure gradient some of these do include the acceleration pressure loss But HYSYS still doesn t consider the kinetic energy term in the energy balance so the some accuracy is sacrificed Aspen Technology, Inc. All rights reserved. 37

38 Into the models HYSYS Compressible Gas Pipe Solves the mass, momentum, and energy equations simultaneously for single phase compressible flow Make sure to update the Properties method to Compressible Gas Do not use for two-phase flow 2018 Aspen Technology, Inc. All rights reserved. 38

39 Multi-phase flow

40 Multiphase Pipe Flow Simultaneous flow of more than one phase or component through pipe Consider conditions where some phase or component separation occurs at scale above molecular level, i.e. not wellmixed Petroleum fluids include oil, water, and gas Key characteristics/parameters of multiphase flow Pressure drop across pipe Flow-rate through pipe Flow geometry Gas Phase Downstream Pressure Upstream Pressure 2018 Aspen Technology, Inc. All rights reserved. 40

41 Challenges of Modeling Multiphase Flow Large number of variables affect pressure drop Thermodynamic and transport properties Interaction of different phases, e.g. interfacial tension Piping material and dimensions Multiphase mixture is compressible Fluid slip Large difference between densities of liquid and gas phases cause gas to overtake or slip by liquid phase Flow patterns Fluid phases can spatially arrange in different manner Bubble Mist Stratified 2018 Aspen Technology, Inc. All rights reserved. 41

42 Steady-State Multiphase Flow Model Treat multiphase fluid as homogeneous fluid (with density r m ) and evaluate energy equation for this hypothetical fluid With known mass flow and inlet pressure, integrate pressure gradient along length of pipe to calculate outlet pressure Pressure gradient along pipe dp dl r g sin m dp dl f r v m dv dl Gravitational Change in potential energy Friction Irreversible losses Depending on application, significance of each term will change Gravitational effects dominate vertical flow through wells and risers Friction and acceleration will be important in high-speed gas flow Acceleration Change in kinetic energy 2018 Aspen Technology, Inc. All rights reserved. 42

43 Case Study 2:Steady State Two Phase Flow Modelling the same pipe with: Pipe Segment Aspen Hydraulics Use 100 cells/segments in both tools Comparing results from different specifications 2018 Aspen Technology, Inc. All rights reserved. 45

44 Example 1 Standard pressure drop calculation Parameters Studied Specify Pressure & Flow at the source (P0, F) Varying flow (F) Comparing the pressure predicted by each model at the sink (P1) Observations Using Beggs & Brill (1979), the predictions match 2018 Aspen Technology, Inc. All rights reserved. 46

45 Example 2 Standard pressure drop calculation Parameters Studied Specify sink pressure & flow (P1,F) Varying flow (F) Comparing the pressure predicted by each model at the source (P0) Observations Using Beggs & Brill (1979), the predictions match 2018 Aspen Technology, Inc. All rights reserved. 47

46 Example 2 (cont.) Observations The temperature (T1) prediction slightly diverge at higher velocity The difference is due to the kinetic energy contribution in Aspen Hydraulics 2018 Aspen Technology, Inc. All rights reserved. 48

47 Case Study on Varying Geometry Data Source Tulsa University Fluid Flow Project (TUFFP) Database 40 experimental data sets data records Two-Phase system Air-Water Air-Oil (lubricants) Air-Kerosene 2018 Aspen Technology, Inc. All rights reserved. 49

48 Case Study on Varying Geometry Horizontal Pipes Data Sets Yang (1996), Meng (1999), Fan (2005), Magrini (2009), and Brito (2012) Tulsa Unified Model Beggs & Brill (1979) Gregory et al. HTFS 2018 Aspen Technology, Inc. All rights reserved. 50

49 Case Study on Varying Geometry Inclined Pipes Data Sets -75 to +75 degrees (426 data points) Tulsa Unified Model Beggs & Brill (1979) Gregory et al. HTFS 2018 Aspen Technology, Inc. All rights reserved. 51

51 Case Study on Varying Geometry Conclusion Understand the limitation of each correlation! Considerations Large choice of correlations available None perform across all conditions because developed using specific set of experimental data Errors in measured data 2018 Aspen Technology, Inc. All rights reserved. 53

Object Oriented Simulation of Multiphase Flow

Object Oriented Simulation of Multiphase Flow P.Klebert and O.J.Nydal Norwegian University of Science and Technology (NTNU) 7491 Trondheim Norway Abstract Pipelines in offshore oil and gas production systems