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SPE 59029

Design and Development of Hydrocarbon Surface Production Facilities and Pipelines


Based on Process And Transport Simulators.
M.P. Castillo, SPE, Instituto Mexicano del Petroleo; M. Murillo, Pemex Exploracion and Produccion Region Sur,and C.
Cabrales, Instituto Mexicano del Petroleo.
Copyright 2000, Society of Petroleum Engineers Inc.
and ordered to justify the new projects and the required
This paper was prepared for presentation at the 2000 SPE International Petroleum Conference investments.
and Exhibition in Mexico held in Villahermosa, Mexico, 1–3 February 2000.

This paper was selected for presentation by an SPE Program Committee following review of Introduction
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to The Region Sur has an importance of first order in the context
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at of the economics and the national politics. From the fiftys the
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
states of Tabasco, North of Chiapas and Veracruz began to
for commercial purposes without the written consent of the Society of Petroleum Engineers is receive strong investments that sponsored the takeoff of this
prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300
words; illustrations may not be copied. The abstract must contain conspicuous zone as international trade pole in base to three factors:
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
• Their geographic location that connects them with large
Summary three ports (Dos Bocas, Pajaritos and Salina Cruz).
Among the main objectives of Pemex Exploracion and
• The great industrial development achieved in the other
Produccion Region Sur is found the analysis of the operation,
subsidiaries of Pemex (Pemex Refinacion, Pemex Gas y
the optimizacion and the modernization of the systems of
Petroquimica Basica and Pemex Petroquimica).
produccion, transportation and distribution of hydrocarbons, in
• The quality of the hydrocarbons, what permits to improve
order to provide better security conditions, efficiency and
the crude mixtures for exportation as well as for the
opportunity, without forgetting the proteccion to the
processing at domestic level.
environment and the society.
In general terms the Region Sur is characterized by generating
For the foregoing, it results from great importance to count on
20 percent of national produccion of oil, 46 percent of the
a methodology for planning the behavior and development of
produccion of the gas, and 16.6 percent of gas liquids.
the infrastructure of produccion and transportation to face
current and future needs, bearing in mind the operational
requirements and quality that demand best engineering
Currently the produccion of gas in the region is of 2 190
practices.
mmpcd in average. Of this volume 86 percent originates of the
Mesozoic and 14 percent of the Tertiary. Concerning to gas
The utilization of Process and Transport Simulators to analyze
liquids the produccion is of 14 725 bpd of which 96 percent
the facilities in the current operation conditions, and to predict
corresponds to the mesozoico and 4 percent to the Tertiary.
their behavior under different stages is a valuable tool that
applied combined with the best practices of engineering
The gas and condensate produced have as final destination the
allows to predict, with meaningful time savings, the necessary
processing gas centers of Cactus, Nuevo Pemex, Cd. Pemex
modifications to be adjusted to the new operative philosophy,
and La Venta. It is convenient to indicate that the Region Sur
without putting on risk the facilities.
receives part from the gas from the Marine Region by Atasta
for its processing in Cd. Pemex, Cactus and Nuevo Pemex.
As added value, the results obtained from the application of
this methodology also contributes to the construction of a data
In general terms the gas and the condensate that are
base, of the facilities of produccion as well of transportation,
transported in the Region Sur are sour and saturated with
of great usefulness for activities related to the maintenance
water, what implies a greater duct and equipment deterioration
programs.
due to corrosion. On the other hand, part of the infrastructure
could be in the limit of its operative life, therefore to prevent
The results of modeling are completed with an economical
any further risk is necessary the substitution of some
analysis in order to find the best alternative to solve a
components.
particular situation. The obtained information is documented
2 M. CASTILLO, M. MURILLO, C. CABRALES SPE 59029

Additionally, the produccion of gas and of condensate tends to Modeling Procedure


reduce, therefore in some instances it must be considered the In figures 2 and 3 are shown the Produccion and
sustitution, relocation or modification of the infrastructure, or Transportation Systems, from which we began construction of
even to propose different alternatives of operation. the models. These figures indicate the way the produccion of
gas and condensated, originated from the different facilities is
Based on all of the above a team of engineers carried out the gathered, and the physical characteristics of the available
modelation of the systems, particularly concerning the pipelines. Finally these volumes of hydrocarbons are
managing of the gas and the condensates in the Region Sur. delivered to the processing gas centers of Cactus, Nuevo
Pemex and Cd. Pemex.
This modelation has the purpouse of detecting bottle necks in
the current infrastructure, and to optimize transportation In agreement with the authorities of Pemex Exploracion and
systems to face future demands. Produccion, the Instituto Mexicano del Petroleo began the
process of modeling with the following objectives:
Description of Process and Transport Simulators
In the market exists a great variety of simulators that have • To reproduce the behavior of the transportation systems,
proven their usefulness in oil industry, particularly with particularly with respect to the cases of two phase flow in
respect to optimize nets of ducts and facilities for which "Retrograde Condensation” phenomena takes
hydrocarbon processing. place.
• To analyze in transportation nets the effect by
In figure 1 are shown the computer programs that were used incorporating greater volumes of hydrocarbons, or decline
an their capacity to reproduce and predict the necessary of the produccion.
operation conditions for the design of produccion and • To detect possible bottle necks.
transportation systems. • To accomplish overall sensibility studies (Technical and
Economical) of the operation of the system.
These simulators were selected in base to the obtained
experiences from their application, that is to say the accuracy Hydrocarbons Characterization
to reproduce the operation conditions as obtained from the In spite of the fact that the characteristics of the products
field. obtained in a production unit depend on the compositional
analisis of each one on the wells that flow to this, by the
Concerning what is referred to the quality and type of difficulty that represents the availability of recent samples, a
informacion fed to the models we can say that this is of three discrimination of the existing informacion is adopted and, as
types: the obtained from the instruments installed in field of the Analisis - PVT - available, through the use of simulators
(Pressure, Temperature and Flow); the mechanical was obtained the necessary characterization for the modeling.
characteristics of the system (Diameter, Length, Thickness, However, in some instances before the absence of exact
Material of Contruction, Right of Way and Topographic information “Black oil” option has ben taken.
Profile); and the Compositional Analysis of the Hydrocarbons
(C1 to C6+, CO2, N2, H2S and water content). In figure 4 is presented an example of the data treatment that
is effected to a Sample - PVT - of a well to obtain the
On the other hand, it is also mandatory to know the corresponding compositional analisis.
produccion forecasts required to evaluate the systems under
different operative stages, and the information obtained from With respect to the transported gas, the chromatographic
calibrating pigs which provides data on the current situacion analisis is preferred the one that routinely is performed in
of the thickness of the pipeline, crucial information to production facilities. The experience has demonstrated the
establish the maximum operating pressure of the pipe, that is usefulness that represents the power to determine with the
pressure for transport. greater possible accuracy the heavy ends, since they influence
accuracy in prediction of condensacion during transportation,
Characterization of fluids as well as the identification of undesirable flow patherns. In
This factor is a key factor for the design and development of the table 1 is shown a typical example of gas composicion
Production and Transportation facilities, since the results that obtained in the region.
are obtained as product from modeling are found intimamente
related to the composition of the fluids processed. Due to the difficulty to determine the concentration of water in
the gas streams produced in production facilities, it is been
For the case of the hydrocarbons processed in production adopted, with good results, to determine this concentracion as
facilities the information of the - PVT Analysis- obtained from of the operation conditions and the composition of the
reservoir samples is used. With respect to gas transportation, hydrocarbons, applying equations of state (Peng-Robinson
cromatographic analysis is been used. and Soave-Redlich-Kwong). The accuracy of this
SPE 59029 DESIGN AND DEVELOPMENT OF HYDROCARBON SURFACE PRODUCTION FACILITIES AND PIPELINES BASED ON SIMULATOR 3

consideration has been corroborated comparing the obtained • Fluid Flow.- There are several field studies that
results from the modeling against information of field in those recommend velocities to design pipelines. In most of the
points where water could be measured in liquid form. cases this recommendations seek to avoid, through the
control of the velocity, erosion, stratificaction of water or
Required Information and Design Criteria solids, and undesirable flow patherns
The simulators are capable of modeling production and .
gathering systems, including within these parallel pipelines or However, in our case, in the one which the systems are
"Loops". existing; that they began their operation in different
conditions from the current; and that in the future is
These simulators report composition of phases, pressure drop, possible that they have to comply with different operation
liquid formation or "Hold Up", flow patterns , transportation conditions, these recommendations have been considered
velocity, and thermophysical properties of the fluids involved as a reference, and the projects accomplished in the
in the design of the equipment. Region Sur have developed their own criteria.

To get this data the following informacion is fed: As a reference we could mention for gas 20-60 FPS and for
liquids 4-10 FPS.
• Composition.- Such as we mention before, for high
molecular weight streams this is obtained from data • Flow Patterns.- As a rule it is considered to avoid
treatment from the - PVT Analisis - to obtain the undesirable flow patterns such as "Slug" and "Plug".
concentration of identificable components asi well as However you dont’n have to forget that in the case of the
pseudocomponents. In the case of the gas streams, light transportation of the associated gas the phenomena of
molecular weight, chromatographic analysis is used "retrograde condensation" which leads to multifhase flow,
directly. the alternative to control the volume transported to avoid
these patterns could be identified in the field by the
• Pressure, Temperature and Flow.- This information is fluctuacion of the operation conditions in the delivery
obtained from operating logs. In those cases when is points at the end of pipe.
intended to operate at different conditions of the current,
is agreed with the operator the range in which these • Validation of the Model.- Once it is fed all the
variables can be modified so that, during the stage of information to the model, a series of runs in the computer
modelacion of stages, are analyzed only those feasible are performed which main objective is to reproduce, as
cases to be carried in practice. close as possible, from the operation conditions of the
system in the origin, the conditions in the extreme of the
• Calculation Methods.- The experience obtained duct.
throughout several years devoted to the modelation of These final conditions commonly are: volumes of liquid
production facilities has carried us to use, for the and gas, pressure and temperature, volumes of liquids
calculation of gas-liquid equilibria, thermophisical displaced by pigs, etc.
properties,Peng Robinson, Soave-Redlich-Kwong, Lee-
Kessler, Grayson Streed. In regard to the viscosity, it has • Operational Philosophy and Production Forecasts.-
been proven that the utilization of experimental Such as we mention before, in order to establish if a
viscosities for heavy fractions is highly advisable. system has the necessary operative flexibility, it is
important to count on with the production forecasts.
In what concerns to the multiphase transport, horizontal or
vertical , it has been used Taitel-Dukler-Barnea, Beggs and This document contains the yearly produccion of
Brill, Dukler-Edton-Flanigan. hydrocarbons during a period of at least 15 years, and
upon using it we will be able to know to identify bottle
• Process Equipment and Right of Way.-In this case it is necks in the system and then to find out the operative or
provided the informacion related to the size of the constructive alternatives to avoid them.
equipment, the internal diameter, length and topographic
profile of the pipeline.
Modeling of Gas Gathering System “Catedral-
• On the other hand, taking into account the characteristics Muspac-Chiapas-Giraldas-Cactus”.
of the right of way, our experience recommends to use
overall heat transfer coefficients “U” of 1.20 and 0.66 Catedral-Muspac.Chiapas-Giraldas-Cactus System is a high
BTU HR FT² ºF/FT for gas and liquid transportation pressure pipeline network which gathers associated gas
respectively. obtained in four production units. The total amount of gas is
4 M. CASTILLO, M. MURILLO, C. CABRALES SPE 59029

delivered at high pressure to be processed in a Gas Processing alternatives to handle hydrocarbons within the gathering
Plant located in Cactus. network.

Figure 5 shows the results obtained when we apply the


methodology for a high pressure sour gas gathering system. Nomenclature

This figure presents a comparison between operating MMSCPD=Million standard cubic feet per day.
conditions and those values obtained by simulation. As we can BPD= Barrels per day
see deviation in the majority of cases remains in aceptable FPS=Feet per second
level, therefore the model is validated. P=Pressure, kg/cm²
T=Temperature, ºC
Figure 6 shows the proposed infraestructure required to CPG= Gas Processing Plant
operate the same system but at lower pressure including some
other separation units. References.

Conclusions 1. John Campbell: Gas Conditioning and Processing Vol I.


1. The use of processing and transportation simulators has 2. J. McHugh:On Target with Rough Gas Engineering and
been of great help to analyze, eliminate bottle necks and Management.
to optimize the current and future facilities for the 3. Gas Processors Suppliers Asociation:Engineering Data
managing of gas and condensate in the Region Sur. Book, 1972.
4. Word Rosen: Gas Processing,1996
2. The decisionmaking to change the philosophy of 5. O. W. Boyd: Petroleum Fluid Flow Systems, 1983.
operation of the facilities, or to justify the construccion of 6. A. Minkkenen: Make Best use of Associated Gas,1981
new infrastructure, preserving the security margins 7. Norma No. 07.3.13, PEP 171,Requisitos Minimos de
recommended to protect the environment and population, Seguridad para el Diseño, Construccion, Operación,
avoiding the deferred produccion, is facilitated with the Mantenimiento e Inspeccion de Tuberias de Transporte, 6ª.
employment of the simulators without putting on risk the Revision, Septiembre 1994.
infrastructure. 8. PEMEX FA-2716: Evaluacion de los Sistemas de
Recoleccion, Transporte y Distribucion de Hidrocarburos
3. It is been proved the usefulness that represents countting en la Region Sur. 1997.
on recent compotional analysis. However it is advisable to 9. PEMEX P-1008: Analisis Tecnico Economico de
detect as much as possible high molecular fractions in the Opciones de Proceso, Transporte y Entrega de Gas y
chromatograph. Condensado en la Coordinacion Tecnica Operativa.1999.

The resource of using a - PVT anlysis - or the option


"Black Oil" leads to greater deviations and alone are
recommended as the last resource, or for very general
studies to explore alternatives of operation.

4. The aplicacion of simulators to plan the development of


the processing infrastructure, with sufficient flexibility to
fulfil future requirements, requires of reliable information
the one which is obtained from an adequate and calibrated
instrumentation in the field.

5. The routine use of simulators for the design of processing


and transportation facilities of hydrocarbons allows the
optimization of the infrastructure making it efficient and
adjusted to the requirements of Pemex Exploracion and
Produccion Region Sur.

6. Nowadays IMP is working in an integral model which


considers the total network of gas an liquids pipelines in
Region Sur. This tool when completed could facilitate
estimation of produccion delivered to gas processing
plants, predict operating conditions required to cope with
the missoperation of a pipeline or failure, and detect best
SPE 59029 DESIGN AND DEVELOPMENT OF HYDROCARBON SURFACE PRODUCTION FACILITIES AND PIPELINES BASED ON SIMULATOR 5

COMPONENT MOL %

N2 1.151
CO2 2.528
H2S 4.656
C1 73.683
C2 10.276
C3 4.375
IC4 0.696
NC4 1.343
IC5 0.421
NC5 0.431
C6+ 0.441

PRESSURE 85 KG/CM2
TEMPERATURE 50 °C

MOLECULAR WEIGHT (GR/GR MOL) 22.253


SPECIFIC GRAVITY (AIR=1) 0.768
DENSITY (LBS/M3) 2.075
PROPANE PLUS (BLS/MMPCD) 53.689
CP GROSS (KCAL/M3) 9951.02
CP GROSS (BTU/FT3) 1118.21

TABLE 1. TYPICAL GAS COMPOSITION

PROCESS TRANSPORT

HYSYS PIPEPHASE
PRO II PIPESIM-NET
ASPEN PLUS PIPEFLOW
SIMPROC LINEAS II

INPUT OUTPUT

FLOW GAS-LIQUID EQUILIBRIUM


COMPOSITION PRESSURE DROP
TEMPERATURE THERMOPHYSICAL PROPERTIES
PRESSURE
FLOW PATTERN
HEAT TRANSFER “U”
OPERATING CONDITIONS ALONG THE
DESIRED FLOW PATTERN
PIPELINE
TOPOGRAPHIC PROFILE
RETROGRADE CONDENSATION
RIGHT OF WAY

FIGURE 1. COMMERCIAL SIMULATORS


6
ATASTA

SEN
36" x 56.5 KM PROVISIONAL LUNA
DOS BOCAS BAT. COMPRESORAS
CUNDUACAN

KM
.4
16" x 5.97 KM KM
KM

x9

24" x 0.5 KM
"
x 92

20
x 92

24" x 5.97 KM
36"

36" x 30.8 KM 36" x 14.8 KM 16" x 0.1 KM


36"

PIJIJE
L-2
L-3

KM AREA DE
9
BELLOTA "x TRAMPAS

36
36 OXIACAQUE

24" x 7.1 KM

"x
65
.7
KM
CARDENAS
C.P.G. CD. PEMEX
NORTE SAMARIA-II

16" x 21 KM
OPERA EN P.I.
REQUERIMIENTO EN A.P. 24" x 79 KM

KM
KM
KM. 77

.7 ER
4.7
36" x 9 KM

14 CH
36" x 70 KM

AREA

x1

" x CAT
"

U
24" x 9.8 KM

6
36" x 10.5 KM NUEVO

3 G-
36

SL
36" x 10.5 KM PEMEX

16" x 14.4 KM
24" x
11 K
M
OPERA EN P.I. PAREDON 24" x 30" x 2.8 KM
10 K T.R.D.
REQUERIMIENTO EN A.P. M
KM 36" x
21 K AREA 24" x 4.7 KM
C.P.G.
16 M
6 "x NORESTE NUEVO PEMEX
12" x 6.46 KM 3 16" x 13 KM C.P.G.
TECOMINOACAN CACTUS

JUJO CACTUS I CACTUS-II


M
AREA
CACTUS IV 10" x 5.5 KM
16" x 10 KM

12" x 8.5 KM

M CACTUS-IV
M. CASTILLO, M. MURILLO, C. CABRALES

24"Ø x 34 KM 30" x 8 KM
24"Ø x 13 KM
36" x 7 KM

30"
x 37
KM

24" x 15.7 KM KM
34
KM "x
x 9 .9 36
24"
15.7 KM
36" x AGAVE
KM CHIAPAS SITIO GRANDE
x 9 .9
36"
MUSPAC GIRALDAS
16" x 10 KM

12

x6
KM
16 SUNUAPA
"Ø EXISTING PIPELINES
x6
KM PIPELINES IN CONSTRUCCION
CATEDRAL PIPELINES IN PLANNING

FIGURE 2. GAS GATHERING SYSTEM. PRESENT AND FUTURE


SPE 59029
RECOMPRESION
ATASTA

BAT. Y COMP. SEN


CUNDUACAN
6" X 44 KM

BELLOTA

8" X
7.1 K
M
KM
KM

9 1.5
91.5

CARDENAS
X

NORTE
16"
16" X

SAMARIA-II

KM
4.9
X
8"
6"X4.4 KM
OPERATION OUTSIDE

KM. 77
24"X79KM

8"
SAMARIA-III C.P.G.

X
KM

KM

28
8" x .7 CD. PEMEX
14

KM
15 K X
M
8"

24" X 10
SLUG-CATCHER 36" X 10.5 KM
8"
PAREDON X 20 12" 16" X 10.5 KM AREA
.9 24" X 70 KM
KM NUEVO
KM AREA 6" X 2 KM PEMEX
14 8"
X X 21 6" X 2 KM
O KM NORESTE BAT.
8"
C.P.G. CACTUS I
CACTUS
TECOMINOACAN JUJO
8" X 1 KM
8" X 6.5 KM
C.P.G.
COMP. NVO. PEMEX
CABEZAL CACTUS I
JUSPI
AREA
CACTUS IV

8" X 7 KM
M
11 K
8" X OPERATION OUTSIDE
(1) CACTUS II
KM
.8 6" X 4.8 KM
32
X KM
8"
1.8 ENTRONQUE
"X2
10

4" X 15 KM
M

8"
GIRALDAS IT
X3
8"X8 K

0K
WO M
RK
8" PIP S A S
X1 EL A
INE N O
0K IL
M
AGAVE

SUNUAPA
SITIO GRANDE

8" X 15 KM
EXISTING PIPE LINE

PIPELINES IN CONSTRUCCION

PIPELINES IN PLANNING
CHIAPAS

FIGURE 3. CONDENSATE GATHERING SYSTEM. PRESENT AND FUTURE


SPE 59029 DESIGN AND DEVELOPMENT OF HYDROCARBON SURFACE PRODUCTION FACILITIES AND PIPELINES BASED ON SIMULATOR 7
8 M. CASTILLO, M. MURILLO, C. CABRALES SPE 59029

START

RESERVOIR PVT ANALYSIS

OPERATING
CONDITIONS

CHECK PROPERTIES
AGAINST EXISTING DATA ON
FIELD

MODELING OF
PRODUCTION FACILITIES

NO
RESULTS MATCH EXISTING MAKE ADJUSTENTS
INFORMATION IN THE FIELD ? IN COMPOSITION.
(MOL %, GOR, ETC)

YES

COMPOSITION OK FOR
FUTURE SIMULATIONS

END

FIGURE 4. PVT ANALYSYS DATA TREATMENT


36"ø
15.7
X Km
36"ø X Km
13
36"ø X 21 Km

M M
CATEDRAL MUSPAC N
C
. 24"ø X Km
13 C.P.G. CACTUS
SLUG -
M
JUSPI

9.9 16"Ø Km X X 36"ø Km 6 M GIRALDAS

CHIAPAS
"A" SECTION "B" SECTION "C" SECTION "D" SECTION

SECTION "A" SECTION "B" SECTION "C" SECTION "D"


CATEDRAL ENVÍO MUSPAC RECIBO MUSPAC ENVIO CHIAPAS RECIBO CHIAPAS ENVÍO GIRALDAS RECIBO GIRALDAS ENVIO CACTUS RECIBO
F P T F P T F P T F P T F P T F P T F P T F P T
FIEL DATA 120 90.0 57 120 85.0 50 330 85.0 54.0 330 84.0 50.0 365 83.0 32.0 365 80.0 29.0 535 80.0 36.0 535 73.0 32.0
SIMULATION 120 90.2 57 120 84.1 46 330 84.1 50.6 330 82.8 46.2 365 82.1 31.7 365 79.8 28.4 535 79.8 34.9 535 71.8 28.0
DESVIATION % ------- 0.2 ------- ------- -1.1 -8.0 ------- -1.1 -6.2 ------- -1.9 -7.6 ------- -1.1 -0.9 ------- -0.3 -2.1 ------- -1.2 -3.1 ------- -1.6 -1.25

FIGURE 5. HIGH PRESURE SOUR GAS GATHERING SYSTEM: CATEDRAL-MUSPAC-CHIAPAS-GIRALDAS-CPG CACTUS,


VALIDATION OF MODEL (80-90 kg/cm2) .
SPE 59029 DESIGN AND DEVELOPMENT OF HYDROCARBON SURFACE PRODUCTION FACILITIES AND PIPELINES BASED ON SIMULATOR 9
10

15.7 X 36"ø
13 X 3 6 Km

36"ø X 21 Km
C.P.G. CACTUS
M M
13 X N
C
. C.P.G. CACTUS
CATEDRAL MUSPAC 24"ø
SLUG - CATCHER
M
JUSPI

6 X 9.9 16"Ø X 36"ø M GIRALDAS


Km Km

CHIAPAS

N
C
.

24"ø X 9.9 Km 24"ø X 15.7 Km 24"ø X 34 Km


M. CASTILLO, M. MURILLO, C. CABRALES

16"ø X 10 Km

EXISTING PIPELINE
SUNUAPA
PROPOSED PIPELINE

FIGURE 6. INTERMEDIATE PRESSURE SOUR GAS GATHERING SYSTEM: CATEDRAL-MUSPAC-CHIAPAS-GIRALDAS-CPG CACTUS,.


PROPOSED NEW PIPELINES (41-51 kg/cm2).
SPE 59029

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