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SS DES-05Design and Operational Study of a300 Km LPG-Pipeline System
Design and Simulation ClosingSession
José Luis Zaragoza y GutiérrezAlexander Bruce MacDonald10/16/13
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
Design and Simulation ClosingSession
José Luis Zaragoza y GutiérrezAlexander Bruce MacDonald10/16/13
Supporting the Industryin Mexico
Consultoría Empresarial Ejecutiva, S.A. de C.V. (CEE)
• Engineering Consulting Firm based in Mexico City
• Founded in 1995 by chemical engineering experts in different fieldswith a solid background working at PEMEX
• CEE provides its expertise on a variety of projects in the Oil, Gas,Energy, and Petrochemical industries
• Projects range from the conceptual business development,engineering studies, planning, economic analysis, basic and detailedengineering, pre-commissioning, training, start-up, performancetests, and computer simulation, among others.
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Consultoría Empresarial Ejecutiva, S.A. de C.V. (CEE)
• Engineering Consulting Firm based in Mexico City
• Founded in 1995 by chemical engineering experts in different fieldswith a solid background working at PEMEX
• CEE provides its expertise on a variety of projects in the Oil, Gas,Energy, and Petrochemical industries
• Projects range from the conceptual business development,engineering studies, planning, economic analysis, basic and detailedengineering, pre-commissioning, training, start-up, performancetests, and computer simulation, among others.
Outline
1. Overall Challenges and Drivers
2. Case Study Overview
3. Scope of Work
4. Simulation
a) Stage 1 – EXCEL
b) Stage 2 – PIPEPHASE + SIM4ME PORTAL
c) Stage 3 – DYNSIM
5. Benefits and Conclusions
Slide 4
1. Overall Challenges and Drivers
2. Case Study Overview
3. Scope of Work
4. Simulation
a) Stage 1 – EXCEL
b) Stage 2 – PIPEPHASE + SIM4ME PORTAL
c) Stage 3 – DYNSIM
5. Benefits and Conclusions
Overall challenges and drivers• Satisfy Mexico’s growing
LPG fuel demand;
• Historically, all existingpipeline systems havebeen owned andoperated by PEMEX
• New injection to themain LPG backbone wasthe first system to beoperated by a privatecompany
• Lack of experience tooperate a LPG-pipelineby the new owner!
• Change in the originaldesign – validate safetyand environmentalcompliance
Tuxpan
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• Satisfy Mexico’s growingLPG fuel demand;
• Historically, all existingpipeline systems havebeen owned andoperated by PEMEX
• New injection to themain LPG backbone wasthe first system to beoperated by a privatecompany
• Lack of experience tooperate a LPG-pipelineby the new owner!
• Change in the originaldesign – validate safetyand environmentalcompliance
Image taken fromsener.gob.mx and modified
©
Poza Rica-Atotonilco LPG Pipeline
Cactus-Guadalajara LPG Pipeline
Refinery
Gas Processing Complex
Tuxpan
Case Study OverviewKey objectives:• Analyze normal, maximum and critical operating conditions to:
• Validate design
• Minimize Capital Expenditure
• Validate a Safe Operation
• Future: Design control philosophy and define start-up procedures
SteadyState andDynamic
SimulationTools Better capital
expendituredecisions
(up to $20M)Increase safetyon the operation
and more…
Slide 6
Key objectives:• Analyze normal, maximum and critical operating conditions to:
• Validate design
• Minimize Capital Expenditure
• Validate a Safe Operation
• Future: Design control philosophy and define start-up procedures
Expertiseand
ConsultingServices
Better capitalexpenditure
decisions(up to $20M)
Increase safetyon the operation
and more…
MecapalapaIntersection,
Puebla(km 34)
IRGEAtotonilco,
Hidalgo(km 232)
Tlautla,Hidalgo
(km 251)
San Agustín,Puebla(km 72)
Cima de Togo,Hidalgo
(km 108)km 1.78
Poza Rica(produced LPG) Cactus-Guadalajara
LPG-Pipeline
Scope of Work
32 km 38 km 36 km 124 km 19 km
10’’ Pipeline with a total length of: 324 km
EB01 EB02 EB03 EB04
AtotonilcoHidalgo
Slide 7
km 0
Tuxpan,(imported LPG)
Tula RefineryEB01A
• 5 pump stations (cap.: 20,000 / 40,000 bpd)
• Pipeline burried 2 - 5 ft
• 25 sectioning + 10 check valves
• Minimum pressure limit: 14 kg/cm2g (200 psig)
• Maximum pressure limit: 100 kg/cm2g (1422 psig)
Poza RicaVeracruz
1,250 data points wereused to mirror the actual
pipeline profile
Specific Objectives 1st Phase
• Analyze…– Maximum/normal/minimum/critical operating conditions at different
scenarios (e.g.: temperature, flow, pressure).– System malfunctions (e.g.: pump failure, valve failure, pipeline rupture,
fluid hammer).– Abrupt flow, temperature and pressure variations.
… to• Confirm the need of an additional pipeline in segment EB01A-
Mecapalapa or propose an alternative solution• Validate the design and location of pumping stations• Validate the control strategy to protect the pumps and the entire
system
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• Analyze…– Maximum/normal/minimum/critical operating conditions at different
scenarios (e.g.: temperature, flow, pressure).– System malfunctions (e.g.: pump failure, valve failure, pipeline rupture,
fluid hammer).– Abrupt flow, temperature and pressure variations.
… to• Confirm the need of an additional pipeline in segment EB01A-
Mecapalapa or propose an alternative solution• Validate the design and location of pumping stations• Validate the control strategy to protect the pumps and the entire
system
Simulation StagesStages
Assumptions/Simplifications
Advantages Disadvantages
1 – EXCEL • Steady-State
• Isothermal
• Readily available
• Simple to program
• (Almost) instantaneous
results
• Not rigorous (very
preliminary results)
• Limited by size of
the spreadsheet
2 – PIPEPHASE
+ SIM4ME
PORTAL
• Steady-State
• Non-Isothermal
• Rigorous
• Friendly interface
• (Almost) instantaneous
results
• Not in real time
• Cannot analyze the
control system
Slide 9
2 – PIPEPHASE
+ SIM4ME
PORTAL
• Steady-State
• Non-Isothermal
• Rigorous
• Friendly interface
• (Almost) instantaneous
results
• Not in real time
• Cannot analyze the
control system
3 – DYNSIM • Dynamic
• Non-isothermal
• More rigorous
• Friendly interface
• Control system analysis
in real time
• Malfunction analysis in
real time
• Speed of calculations
limted by computer’s
processing capacity
Every simulation stageget more and more
rigorous.
Excel
Simulation Stage 1Steady State – Isothermal
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
Steady-State, Isothermal Modeling
Slide 11
Screenshots of the Excel Simulator
Slide 12
The pressure drop of one segmentfor a given flow
Slide 13
Discharge Pressure Analysis
Minimum Pump Discharge Pressure (kg/cm2g)
FlowScenarios
(1000 BPD)EB01 EB01A EB02 EB03 EB04
Poza Rica:Tuxpan:
200 81.2 - 81.5 45.8 51.1
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Poza Rica:Tuxpan:
020 - 86.3 81.5 45.8 51.1
Poza Rica:Tuxpan:
2020 90.2 95.3 90.0 74.8 52.2
Poza Rica:Tuxpan:
040 - 110.5 90.0 75.0 52.2
Pressure Drop vs Flow
Slide 15
PIPEPHASE + SIM4ME PORTALSimulation Stage 2:Steady State – Non-isothermal
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
PIPEPHASE considerations:
Pipe length, diameter, thickness, elevation change Fluid Composition Thermodynamics Pressure drop correlation Pump operating curves (flow rate, head, efficiency). Set point Exact location of devices Heat transfer Fluids Mixture
Slide 17
Pipe length, diameter, thickness, elevation change Fluid Composition Thermodynamics Pressure drop correlation Pump operating curves (flow rate, head, efficiency). Set point Exact location of devices Heat transfer Fluids Mixture
SIM4ME PORTAL
• Interface between Invensyssimulation software and EXCEL
• It has a lot of applications
• In our particular case, it wasused to create a simple,intuitive simulator built-inEXCEL for a non-experienceduser in PIPEPHASE.
• It brings the best of bothworlds together:
− The rigorousness ofPIPEPHASE
− The familiarity of EXCEL
Slide 18
• Interface between Invensyssimulation software and EXCEL
• It has a lot of applications
• In our particular case, it wasused to create a simple,intuitive simulator built-inEXCEL for a non-experienceduser in PIPEPHASE.
• It brings the best of bothworlds together:
− The rigorousness ofPIPEPHASE
− The familiarity of EXCEL
SIM4ME PORTAL SimulatorScreenshot of data input:
• Source flows
• Source temperatures
• Source pressures
• Source compositions
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Screenshot of data output:
• Sink flows
• Sink temperatures
• Sink pressures
• Sink compositions
SIM4ME PORTAL SimulatorScreenshot of data input and output:
Pumpsuctionpressureanddischargepressure
Notes
Link to seepump curves
Slide 20
Pipelinesegmentpressuredrops
Convergenceindicator
Links to seepressureprofiles
SIM4ME PORTAL Simulator
0
200
400
600
800
1,000
1,200
1,400
0
500
1,000
1,500
2,000
2,500
3,000
0+214
2+768
5+089
6+536
8+435
9+769
11+806
13+649
14+997
16+971
18+856
20+504
22+252
24+423
26+311
28+036
30+249
32+940
37+025
40+761
42+853
46+378
50+064
52+551
55+225
57+172
59+269
60+991
61+649
62+513
63+220
64+319
67+318
69+391
70+736
72+917
74+998
77+146
79+042
80+883
81+646
82+829
86+191
88+816
91+455
93+519
96+006
99+705
102+654
104+371
105+989
110+285
116+857
122+001
126+847
133+274
143+898
151+618
161+454
173+896
179+482
183+394
188+570
197+178
209+064
219+487
223+725
228+297
235+659
243+159
Presión (psig)Elevación (m)
Perfil de Elevación y PresionesPoza Rica - Tlautla
EB-01
Poza Rica
EB-02
EB-03
EB-04
Presion
Elevación
Screenshot of data output:Pipeline elevation and pressure profiles
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0
200
400
600
800
1,000
1,200
1,400
0
500
1,000
1,500
2,000
2,500
3,000
0+214
2+768
5+089
6+536
8+435
9+769
11+806
13+649
14+997
16+971
18+856
20+504
22+252
24+423
26+311
28+036
30+249
32+940
37+025
40+761
42+853
46+378
50+064
52+551
55+225
57+172
59+269
60+991
61+649
62+513
63+220
64+319
67+318
69+391
70+736
72+917
74+998
77+146
79+042
80+883
81+646
82+829
86+191
88+816
91+455
93+519
96+006
99+705
102+654
104+371
105+989
110+285
116+857
122+001
126+847
133+274
143+898
151+618
161+454
173+896
179+482
183+394
188+570
197+178
209+064
219+487
223+725
228+297
235+659
243+159
Presión (psig)Elevación (m)
Perfil de Elevación y PresionesPoza Rica - Tlautla
EB-01
Poza Rica
EB-02
EB-03
EB-04
Presion
Elevación
Comparison Between EXCEL andPIPEPHASE Steady-State Simulations
‘‘We need heuristic reasoning when we construct a strictproof as we need scaffolding when we erect a building…Heuristic reasoning is good in itself. What is bad is tomix up heuristic reasoning with rigorous proof. What isworse is to sell heuristic reasoning for rigorous proof’’.
- George Polya
How to Solve It (1945)
• The results obtained with EXCEL and PIPEPHASE are very similar inthis particular case.
So why bother?…
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‘‘We need heuristic reasoning when we construct a strictproof as we need scaffolding when we erect a building…Heuristic reasoning is good in itself. What is bad is tomix up heuristic reasoning with rigorous proof. What isworse is to sell heuristic reasoning for rigorous proof’’.
- George Polya
How to Solve It (1945)
DYNAMIC SIMULATION - DYNSIMSimulation Stage 3:Dynamic – Non-isothermal
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
DYNSIM considers…
Everything PIPEPHASE takes into account plus…
• Time varying effect• Calculations performed every 0.25 seconds at every point
• Controllers (tuning constants, algorithm, limits)
• Control valves
• Equipment detailed data
• Operations constraints
• Malfunctions
Slide 24
Everything PIPEPHASE takes into account plus…
• Time varying effect• Calculations performed every 0.25 seconds at every point
• Controllers (tuning constants, algorithm, limits)
• Control valves
• Equipment detailed data
• Operations constraints
• Malfunctions
Cool Features
• Snapshots – Initial Conditions
• Trends
• Data Historian
• Cross Reference
Slide 25
• Snapshots – Initial Conditions
• Trends
• Data Historian
• Cross Reference
Visualizing the Results
Theinformationsaved via theDATAHISTORIANwas furtheranalyzed withMATLAB.
Videos wererecorded foreachsimulatedscenario.
Slide 26
Theinformationsaved via theDATAHISTORIANwas furtheranalyzed withMATLAB.
Videos wererecorded foreachsimulatedscenario.
Benefits and Conclusions
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
MecapalapaIntersection,
Puebla(km 34)
IRGEAtotonilco,
Hidalgo(km 232)
Tlautla,Hidalgo
(km 251)
San Agustín,Puebla(km 72)
Cima de Togo,Hidalgo
(km 108)km 1.78
Poza Rica(produced LPG) Cactus-Guadalajara
LPG-Pipeline
Benefits of using simulation
32 km 38 km 36 km 124 km 19 km
10’’ Pipeline with a total length of: 324 km
EB01 EB02 EB03 EB04
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km 0
Tuxpan,(imported LPG)
Tula RefineryEB01A
• An additional pipeline was not needed
• Problem can be solved adding a pump station in
Mecapalapa
• Control valves at pump discharge were also
necessary
Benefits of Using PIPEPHASE
• Steady State Simulation - PIPEPHASE
− A parallel pipeline was not necessary, and the high pressureproblem can be solved by installing an intermediate pumpingstation in Mecapalapa… saved a huge capital investment… ≈20million USD!
− We were able to identify critical points at different operationconditions very easily and quickly
• Confirm that the selected pumps were adequate
• Evaluate the effects of changing T, P, F, and zi at the sources
• Select an adequate set point for the controllers so that the systemfunctions properly and safely.
• Allow other users with minimal or null experience in PIPEPHASE to runsimulations via the PIPEPHASE-EXCEL interface created with SIM4MEPORTAL.
Slide 29
• Steady State Simulation - PIPEPHASE
− A parallel pipeline was not necessary, and the high pressureproblem can be solved by installing an intermediate pumpingstation in Mecapalapa… saved a huge capital investment… ≈20million USD!
− We were able to identify critical points at different operationconditions very easily and quickly
• Confirm that the selected pumps were adequate
• Evaluate the effects of changing T, P, F, and zi at the sources
• Select an adequate set point for the controllers so that the systemfunctions properly and safely.
• Allow other users with minimal or null experience in PIPEPHASE to runsimulations via the PIPEPHASE-EXCEL interface created with SIM4MEPORTAL.
Benefits of using DYNSIM
• Identify that control valves at discharge were also necessary – avoiddamage to very critical and expensive equipment (justify theinvestment of the study)
• Preliminary tuning of the controllers; it is better to find out potentialerrors on the simulator than in real life.
• Locate critical points for critical scenarios and estimate the availableresponse time before dangerous conditions are reached.
• The Operation Philosophy can be designed, tested, and re-designed(if necessary) so that it is quantitatively proven to be effective andefficient… We’re testing on the computer and not in the field.
• Ability to connect to an HMI (Excel), so the operators can be trainedon a software based solution instead of the real DCS; it is better tolearn from mistakes on a simulator than in real life.
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• Identify that control valves at discharge were also necessary – avoiddamage to very critical and expensive equipment (justify theinvestment of the study)
• Preliminary tuning of the controllers; it is better to find out potentialerrors on the simulator than in real life.
• Locate critical points for critical scenarios and estimate the availableresponse time before dangerous conditions are reached.
• The Operation Philosophy can be designed, tested, and re-designed(if necessary) so that it is quantitatively proven to be effective andefficient… We’re testing on the computer and not in the field.
• Ability to connect to an HMI (Excel), so the operators can be trainedon a software based solution instead of the real DCS; it is better tolearn from mistakes on a simulator than in real life.
Conclusions• The less simplifications a user makes, the more accurate the
simulation becomes… but simplifications are necessary to get started.
• Computer simulation is not a task in itself; it’s a tool which allows youto properly complete a task… Computer simulation is just tooimportant to be isolated from other project tasks!
• Simulators help in identifying and understanding to a greater extentthe system’s critical variables; and in doing so, also help in optimizingthe system’s configuration, equipment and operating conditions.
• It’s better to learn from mistakes made in a simulator than mistakesmade in real life.
• Computer simulators complement an engineer’s sound judgement.
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• The less simplifications a user makes, the more accurate thesimulation becomes… but simplifications are necessary to get started.
• Computer simulation is not a task in itself; it’s a tool which allows youto properly complete a task… Computer simulation is just tooimportant to be isolated from other project tasks!
• Simulators help in identifying and understanding to a greater extentthe system’s critical variables; and in doing so, also help in optimizingthe system’s configuration, equipment and operating conditions.
• It’s better to learn from mistakes made in a simulator than mistakesmade in real life.
• Computer simulators complement an engineer’s sound judgement.
Next Steps – 2nd Phase
In the future the simulation model can be used to:• Establish the start-up protocols.• Establish the Control Philosophy and Safety Philosophy that:
– Maintains optimum conditions.– Prevents and fixes the malfunctions.
• Train and evaluate technical operators and process engineers.
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In the future the simulation model can be used to:• Establish the start-up protocols.• Establish the Control Philosophy and Safety Philosophy that:
– Maintains optimum conditions.– Prevents and fixes the malfunctions.
• Train and evaluate technical operators and process engineers.
Teamwork!
Invensys
Simulation tools(PIPEPHASE,
SIM4ME PORTAL,DYNSIM)
CEE
Experience, background,operational expertise,
sound judgement
PEOPLE
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Invensys
Training ,Technical Support
and Service
CEE
End user relationship(understanding the
client’s needs)
PEOPLE
Please Send Your Questions AndComments To:
Consultoría Empresarial Ejecutiva, S.A. de C.V.
José Luis Zaragoza y Gutiérrez [email protected]
Alexander Bruce MacDonald [email protected]
Invensys
Lourdes Reyes [email protected]
Gerardo Yañez [email protected]
Slide 34
Consultoría Empresarial Ejecutiva, S.A. de C.V.
José Luis Zaragoza y Gutiérrez [email protected]
Alexander Bruce MacDonald [email protected]
Invensys
Lourdes Reyes [email protected]
Gerardo Yañez [email protected]
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