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Gas Gathering
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Workshop
In this example, a gas 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.

Figure 1

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. 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 modeled 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 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
After you have completed this module, you will be able to use the Pipe Segment in
Aspen HYSYS to model pipelines.

Prerequisites
Before beginning this module, you need to know how to add streams and unit
operations. You also need to complete the Oil Characterization Module.

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.

Branch Segment Length Elevation Elevation

meters meters (feet) Change
(feet) meters (feet)
Branch 1 GasWell 1 639 (2095)
1 150 (500) 645 (2110) 6 (15)
2 125 (410) 636.5 (2089) -8.5 (-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) 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

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Building the Simulation

The gas field will be modeled using the Peng-Robinson property package.

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

The following components should display in the fluid package:

Nitrogen n-Pentane
H2S n-Hexane
CO2 C7+*
If you are using Field units,
the oil components will Methane H2O
have different names,
corresponding to the Ethane NBP[0]92*
different NBP.
Propane NBP[0]171*
i-Butane NBP[0]243*
n-Butane NBP[0]322*
i-Pentane NBP[0]432*

The four streams should have the following values:

GasWell 1 GasWell 2 GasWell 3 GasWell 4

Temperature °C (°F) 40 (105) 45 (115) 45 (115) 35 (95)
Pressure kPa (psia) 4135 (600) 3450 (500) <empty> <empty>
Flow kgmole/h 425 (935) 375 (825) 575 (1270) 545 (1200)
(lbmole/hr)

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 online 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 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 in the following figure:

Figure 2

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Parameters page
On this page, you can select the gradient method that 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
For single phase streams,  Tacite Hydrodynamic Module
the Darcy equation is used
for pressure drop  Tulsa99
predictions.
For all of the pipes in this example, use the Beggs and Brill correlation 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.

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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.

In this cell... Enter...

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

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

5. Select Schedule 40 as the Pipe Schedule.

Figure 3
Aspen HYSYS contains a
database for three pipe
schedules, 40, 80, and
160.

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 Aspen HYSYS.

7. Use the default Pipe Material, Mild Steel, and the default Roughness, 4.572e- 5
m (0.0018 inch).

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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)

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

Figure 4

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

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Heat Transfer page

On this page, you select the method that Aspen 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.
o 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.
o 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.
o 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.
o 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. On the Rating page, click Heat Transfer.

When using the Estimate
HTC option, you have to
10. Switch to the Overall HTC radio button, and enter an Ambient Temperature of
specify the Ambient Temp 5°C (40°F).
on the Overall HTC page

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11. Switch to the Estimate HTC page, and complete it as shown in the following
figure:

Figure 5

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)
Schedule 40
Heat Transfer
Estimate the Inner, Outer, and Pipe
Wall HTC
5° C 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)

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In this cell... Enter...

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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In this cell... 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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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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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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Analyzing the Results

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
 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 6

Figure 7

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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?
Figure 8

Learn how to interpret the warning message.

What is the meaning of the warning message? How to resolve it?

______________________________________________

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 Aspen 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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