Gas Gathering Exercise

Workshop
Gas fields with many wells close together will often have a network of pipelines to transfer the gas from outlying wells to a common processing facility. The facilities are used to maintain a dew point specification and to compress and inject the gas into a processing facility or pipeline. There are seven wells whose flowrates are dependent on the wellhead pressure this is modelled using the Spreadsheet operation. The gas from each well is heated, and several Pipe Segments transfer the gas to the processing facility. A Three-Phase Separator removes hydrocarbon liquids and free water from the gas stream, and the gas is further dried to meet a dew point condition of 0 F at a pressure of 1 atm.

Building the Simulation

Component Methane Ethane Propane i-Butane n-Butane i-Pentane n-Pentane n-Heptane (C6+) CO2 H2O Mole Fraction 0.8805 0.0639 0.0197 0.0049 0.0049 0.0020 0.0020 0.0059 0.0098 0.0064

The gas field and accompanying facilities will be modelled using the Peng-Robinson property package. Select the components and specify the composition and parameters of all of the streams noted below. Note that the Molar Flows are initial estimates; they are a function of the Wellhead Pressures, which will be back-calculated from the pressure of the stream entering the INLET SEP operation. Clone the Field unit set with the molar flow changed to MMSCFD (this will make the Spreadsheet calculations easier).

Hint: Once you have entered the composition for stream 1-2, use the Copy Stream Specs From command on the stream view of the new streams to transfer the composition from stream 1-2 to the rest of the streams.
Name Temperature [F] Molar Flow [MMscfd] Compositions 1-2 200.00 8.00 2-2 250.00 2.00 3-2 4-2 5-2 <empty> 140.00 160.00 15.00 6.00 3.00 See Molar Compositions above 6-2 <empty> 12.00 7-2 60.00 10.00

Install material streams WHD-1, WHD-2, WHD-3, WHD-4, WHD-5, WHD-6 and WHD-7. A spreadsheet will be used to calculate the molar flows of these well streams; they do not have any specifications. Add the heater operations listed below. Specify the temperature of the inlet streams to all of the heaters (7 streams in total) as 20 F, the temperature at which the gas emerges from the wellhead.
HEATER CONNECTIONS Feed Stream Product Stream Energy Stream PARAMETERS Pressure Drop Duty HEATER CONNECTIONS Feed Stream Product Stream Energy Stream PARAMETERS Pressure Drop Duty HEATER CONNECTIONS Feed Stream Product Stream Energy Stream PARAMETERS Pressure Drop Duty LH-1 1-1 1-2 LH1-E 10 psi <empty> LH-4 4-1 4-2 LH4-E 10 psi <empty> LH-7 7-1 7-2 LH7-E 10 psi <empty> HEATER CONNECTIONS Feed Stream Product Stream Energy Stream PARAMETERS Pressure Drop Duty HEATER CONNECTIONS Feed Stream Product Stream Energy Stream PARAMETERS Pressure Drop Duty LH-2 2-1 2-2 LH2-E 10 psi <empty> LH-5 5-1 5-2 LH5-E 10 psi <empty> HEATER CONNECTIONS Feed Stream Product Stream Energy Stream PARAMETERS Pressure Drop Duty HEATER CONNECTIONS Feed Stream Product Stream Energy Stream PARAMETERS Pressure Drop Duty LH-3 3-1 3-2 LH3-E 10 psi <empty> LH-6 6-1 6-2 LH6-E 10 psi <empty>

The gas wells will be simulated in a spreadsheet. Open the Spreadsheet property view to the Spreadsheet page, provide the appropriate titles in column A and list the gas wells (1-7) across the columns (as shown below). You may need to change the number of columns to 8 (on the parameters page of the Spreadsheet). For each well: Provide the appropriate value for Wellhead Absolute Open Flowrate (Vaof) in row 2 (see table at side). For all wells, provide a Wellhead Shut-in Pressure (Psi) of 2000 psia in row 3.
Well 1 2 3 4 5 6 7 Wellhead AOF (MMscfd) 8 2 15 6 3 12 10

Import the pressure of streams 1-2, 2-2, 3-2, 4-2, 5-2, 6-2 and 7-2 into cells B4-H4 inclusive. You can import the pressures by right clicking on the appropriate cell and choosing Import Variable. The pressure is used in the calculation of the potential flowrate from the well (make sure your chosen units are Field with MMSCFD). In order to calculate the flowrate, Caof must first be calculated: C aof = In cell B5, enter the following formula: =B2/(B3^2) Vaof Psi2

Using the appropriate column reference, enter the same formula for the rest of the Wells (e.g. for Well No. 2, enter =C2/(C3^2)). The calculated flowrate (Vp) is calculated as follows:
2 V p = C aof Psi2 Pwhf

In cell B6, enter the following formula: =B5*((B3^2)-(B4^2)) Using the appropriate column reference, enter this same formula for the rest of the wells (e.g. - for Well No. 2, enter =C5*((C3^2)-(C4^2)). Export the Calculated flow rate from cell B6 into the Molar Flow cell of the well stream WHD-1. Export cells C6-H6 to their respective well streams (i.e. Export C6 to WHD-2, Export D6 to WHD-3, and so on). Click the right mouse button on the appropriate cell to access the Export option. Note: The wellhead Pressures and Calculated Flow Rates will initially be <empty>.
A 1 2 3 4 5 6 WellHead AOF (MMscfd) Wellhead SIP (psia) Wellhead Pressure (psia) Caof Calc Flowrate (MMscfd) B Gas Well 1 C Gas Well 2 D Gas Well 3 E Gas Well 4 F Gas Well 5 G Gas Well 6 H Gas Well 7

MIXER CONNECTIONS Inlet:

M-7 3-4 4-3 6-4 7-2 INLET

Install Mixer operation M-7 to combine the incoming streams from the outlying wells. M-7 is the main mixing point for the incoming streams; therefore set the Pressure Assignment to Equalize All.

Flowlines extending from the central site (M-7) to each of the individual wells are modelled next with Pipe Segment Equalize All operations. Because of the varied terrain, both the inner and outer heat transfer coefficients for the line segments will be estimated for all lines.
Outlet: PARAMETERS Pressure Assignment:

Install the following pipe segments

PIPE SEGMENT FL-1 CONNECTIONS Feed 1-2 Product 1-3 Energy FL1-E PARAMETERS Pipe Flow Gregory Aziz Mandhane Correlation SIZING Material Mild Steel Length 10560 ft Elevation 0 ft Pipe Schedule Schedule 40 Nominal 6.00in Diameter HEAT TRANSFER Ambient 32F Temperature (Global) Estimate Inner HTC Estimate Outside HTC Ground Type Moist Clay PIPE SEGMENT FL-4 CONNECTIONS Feed 4-2 Product 4-3 Energy FL4-E PARAMETERS Pipe Flow Gregory Aziz Mandhane Correlation SIZING Material Mild Steel Length 7920 ft Elevation 0 ft Pipe Schedule Schedule 40 Nominal 4.00in Diameter HEAT TRANSFER Ambient 32F Temperature (Global) Estimate Inner HTC Estimate Outside HTC Ground Type Moist Clay PIPE SEGMENT FL-2 CONNECTIONS Feed 2-2 Product 2-3 Energy FL2-E PARAMETERS Pipe Flow Gregory Aziz Mandhane Correlation SIZING Material Mild Steel Length 7920 ft Elevation 100 ft Pipe Schedule Schedule 40 Nominal 3.00in Diameter HEAT TRANSFER Ambient 32F Temperature (Global) Estimate Inner HTC Estimate Outside HTC Ground Type Dry Sand PIPE SEGMENT FL-5 CONNECTIONS Feed 5-2 Product 5-3 Energy FL2-E PARAMETERS Pipe Flow Gregory Aziz Mandhane Correlation SIZING Material Mild Steel Length 5280 ft Elevation -30 ft Pipe Schedule Schedule 40 Nominal 3.00in Diameter HEAT TRANSFER Ambient 32F Temperature (Global) Estimate Inner HTC Estimate Outside HTC Ground Type Wet Peat PIPE SEGMENT FL-3 CONNECTIONS Feed 3-3 Product 3-4 Energy FL3-E PARAMETERS Pipe Flow Gregory Aziz Mandhane Correlation SIZING Material Mild Steel Length 5280 ft Elevation 0 ft Pipe Schedule Schedule 40 Nominal 8.00in Diameter HEAT TRANSFER Ambient 32F Temperature (Global) Estimate Inner HTC Estimate Outside HTC Ground Type Moist Sand PIPE SEGMENT FL-6 CONNECTIONS Feed 6-3 Product 6-4 Energy FL3-E PARAMETERS Pipe Flow Gregory Aziz Mandhane Correlation SIZING Material Mild Steel Length 5280 ft Elevation -10 ft Pipe Schedule Schedule 40 Nominal 6.00in Diameter HEAT TRANSFER Ambient 32F Temperature (Global) Estimate Inner HTC Estimate Outside HTC Ground Type Wet Sand

Note: To add a pipe segment click Append Segment. The Pipe schedule and nominal diameter can be found by clicking View Segment. The ambient temperature can be specified in the Overall HTC tab of the Heat Transfer page, with the other heat transfer information specified in the Estimate HTC tab. Add mixers (M-3 and M-6) to combine the flows from remote wells in a common line with the product from the well closer to the plant site. As with M-7, specify that the pressures in all the lines are Equalized.
MIXER CONNECTIONS Inlet: M-3 3-2 2-3 1-3 3-3 MIXER CONNECTIONS Inlet: M-6 6-2 5-3

Outlet: PARAMETERS Pressure Assignment: Equalize All COMMENTS Specify temperature of stream 3-3 at 80 F

Outlet: 6-3 PARAMETERS Pressure Assignment: Equalize All COMMENTS Specify temperature of stream 6-3 equal to 85 F

After the piping network is complete, install the Adjust operations according to the table below to ensure that the gas flows entering the pipeing network are adjusted to equal the values calculated by the Gas Well operations. Before installing the Adjusts, go into Hold mode. Ensure that you press the Start Button of every Adjust after you have installed it.
Name Adjusted Variable Molar Flow of Stream 1-2 2-2 3-2 4-2 5-2 6-2 7-2 Target Variable Molar Flow of Stream 1-2 2-2 3-2 4-2 5-2 6-2 7-2 Target Molar Flow of Stream WHD-1 WHD-2 WHD-3 WHD-4 WHD-5 WHD-6 WHD-7 Tolerance MMscfd 0.10 0.10 0.10 0.10 0.10 0.10 0.10 Step Size MMscfd 4.00 1.00 7.00 3.00 1.00 6.00 5.00 Simultaneous Simultaneous Simultaneous Simultaneous Simultaneous Simultaneous Simultaneous Method

ADJ-1 ADJ-2 ADJ-3 ADJ-4 ADJ-5 ADJ-6 ADJ-7

The piping network is now complete. To initiate the calculations of the flowrates from the wells, the pressure of the INLET stream should be specified to be 200psia. To complete the installation of facilities, install the rest of the operations as outlined below.
3-PHASE SEPARATOR CONNECTIONS Feed Vapour Outlet Light Liquid Outlet Hvy Liquid Outlet PARAMETERS Pressure Drop INLET SEP INLET WET GAS LIQUIDS WATER KO 0 psi COMPONENT SPLITTER CONNECTIONS Inlet Ohd Outlet Btms Outlet SPLITS DRY GAS, H2O DRY GAS, all other components DEHY UNIT WET GAS DRY GAS H2O REMOVED 0.9 1.0

Note: the Dehyd unit H2O split is only a first estimate

1 2 3 4 5

A Wet Gas Temperature Dry Gas Temperature Wet Gas Pressure Dry Gas Pressure

B =B1-3

Another Spreadsheet should be set up to set the pressure and temperature of the DRY GAS stream (we will leave the temperature and pressure of the H2O REMOVED stream blank).

=B4-10

The Spreadsheet should be set up such that the temperature and pressure of the DRY GAS are 5F and 10 psi less than that of the WET GAS respectively. Values for cell B1 and B4 should be imported from stream WET GAS and cells B2 and B5 should be exported into stream DRY GAS. Install the Compressor and Cooler operations as outlined below:
COMPRESSOR CONNECTIONS Inlet Outlet Energy PARAMETERS Adiabatic Efficiency COMP DRY GAS DISCHARGE COMP-E 75% COOLER AFTER COOLER CONNECTIONS Inlet DISCHARGE Outlet SALES Energy AFT COOLER DUTY PARAMETERS Pressure Drop 10 psia

A Mole Balance operation (DEW-PT(TST)) will be used determine the amount of water removed in DEHY UNIT. DEW-PT(TST) transfers the composition of the sales gas stream SALES to the dew point test stream DEW POINT. The pressure of DEW POINT is set to 1 atm and the vapour fraction is set to 1.0 to establish a dew point condition. An Adjust operation, DEW-PT(CTL), modifies the H2O split in the DEHY UNIT to achieve the desired dew point condition on the sales gas. The sales gas (SALES) has a temperature and pressure of 200 F and 900psia.
MOLE BALANCE DEW-PT(TST) CONNECTIONS Feed SALES Outlet DEW POINT COMMENTS Specify the vapour fraction and pressure of stream DEW POINT as 1 and 1 atm ADJUST CONNECTIONS Adjusted Variable Target Variable Target PARAMETERS Tolerance Step Size Solution Type DEW-PT(CTL) DEHY UNIT, Ohd Fraction (H2O) DEW POINT, Temperature 0 F 0.10 F 0.1 SECANT